Methodology and computer-based tools for re-engineering a custom-engineered product line

ABSTRACT

An in-depth review of a product line is conducted, including customer interviews, in order to identify customer specifications that are more complex than customer needs. Customer needs are quantified, and a reduced set of standard product configuration classes are selected so that about 80% of customer orders based on actual customer needs can be satisfied by the standard product configuration classes, and the remaining orders can be satisfied by custom design. Major components in the standard products are themselves standardized. Manufacture of the standard product is optimized for a one-day manufacturing cycle and separated from the manufacture of the custom designed product. A sales office and manufacturing plant roll-out schedule is implemented and managed by computer-based spreadsheet tools. A product configuration computer program module is interfaced between a product selector and a materials management (MRP) system in order to automate the process of entering orders, designing the standard product, ordering parts, and scheduling assembly of standard product.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to products that are assembled in variousconfigurations to satisfy customer orders.

2. Description of the Related Art

Custom design and assembly has been a traditional way of satisfyingindividual customer orders for complex products. A switchboard is anexample of such a complex product. A switchboard is a kind of electricalpower distribution unit. Electrical power to a building flows from highvoltage utility lines to step-down transformers, from the transformersto one or more switchboards, and from the switchboards to branch ordistribution circuits for lighting, heating and air conditioning,elevators, pumps, and electrical outlets. The switchboards includeutility metering devices, mains protection devices, and branch ordistribution protection devices. Each switchboard may have only utilitymetering devices, only mains protection devices and only branch ordistribution protection devices, or various combinations of thesedevices. Each switchboard includes a metal box typically mounted as afree standing unit on the floor of a utility room in the building. Aswitchboard typically has a current rating of 600 to 4000 amperes. Avery large building or installation such as an airport will typicallyhave a number of switchboards.

Traditionally, a customer through a sales person provided specificationsfor a switchboard to an order engineer. The order engineer customdesigned the entire switchboard using a software tool. There aremillions of possible switchboard configurations, about 3,000 of whichwere designed annually. About 30% of the time, the order engineer woulduse an existing standard switchboard configuration. The other 70% of thetime, the order engineer would custom engineer a new configuration.Custom designs were almost never re-used. The components were thenfabricated, purchased, or taken from inventory, and then assembledaccording the desired switchboard configuration.

The software tool used by the order engineer was a kind of order entrycomputer system. An example of such an order entry system is describedin Geier et al., U.S. Pat. No. 4,984,155 entitled "Order Entry SystemHaving Catalog Assistance," incorporated herein by reference, andPhillips et al., U.S. Pat. No. 5,047,959 entitled "Flexible DataDisplay," incorporated herein by reference. Once the order engineerchose the components to be custom assembled into a switchboard, thesoftware tool generated a bill of materials to be used by a materialsmanagement (MRP) computer system. The software tool was automaticallylinked to the MRP system. The MRP system managed inventory, orderedparts, and managed production capacity. The MRP system ensured that allof the components needed for assembling the switchboard were availableat or delivered to an assembly location by the time when the switchboardwould be scheduled for assembly.

The switchboard market is rather mature. It is a very competitivemarket. The complexity of the product has traditionally had a strongimpact on the profitability of the switchboard business. Computer-basedtools and modern management techniques, such as flexible manufacturing,just-in-time inventory, component count and cost reduction programs, anda total customer satisfaction objective, have been applied over theyears with some success to deliver a quality product at a reasonableprice. Small players have survived in the market due to theirflexibility, short lead-times, low labor costs, and close customerrelationships.

SUMMARY OF THE INVENTION

In order to re-engineer a product line for items that are assembled inrespective configurations to satisfy individual orders, an in-depthreview of the manufacturing and sales of the product is conducted.Customers are interviewed to determine any discrepancies between theiractual needs and the needs expressed in customer specifications for theproduct, in order to identify customer specifications that are morecomplex than the customer needs. The complexity is quantified andexpressed by a histogram or graph of the frequency of assembly hours forcustom design configurations in an ensemble of items sold over a periodof time. This histogram identifies specific product configurations thatare the least complex and the most frequent, and the productconfigurations that are the most complex and the least frequent.Customer needs are quantified and classified in order to identifyspecific product configurations that can satisfy the most frequentcustomer needs. The more frequent and less complex configurations aregrouped into standard product configuration classes, and standardizedwith an understanding of the customers' actual needs and how componentscan be physically assembled to satisfy the customers' actual needs. Thestandard configuration classes may also include new standard designs,which may be submitted to customers for approval before any orders forthe standard product are placed by the customers.

If a customer's actual needs can not be satisfied by an item assembledfrom the standard product configuration classes, then the customer'sactual needs will be satisfied by custom design and assembly. A reducedset of standard product configuration classes is selected so that about80% of customer orders based on actual customer needs can be satisfiedby the standard product configuration classes, and the remaining orderscan be satisfied by custom designs. Major components of the product arethemselves standardized, which involves reducing the number of suchstandard components and modifying the standard components to have awider range of applicability.

The manufacture of the standard product is optimized and separated fromthe manufacture of the custom designed product. The standard product isscheduled for manufacture in a shorter cycle time than the customproduct. Preferably, the standard product is manufactured in about oneday prior to the delivery date requested by the customer. Pricing chosenfor the various possible product configurations is more fairly based onthe actual customer demand for and the cost of supplying each possibleproduct configuration. A premium price can be established for an ordertime to delivery time substantially shorter than the time that isgenerally required in the industry for designing and manufacturing acustom product.

A sales office and manufacturing plant roll-out schedule is establishedfor implementation of the new product sales and production methodology.Computer-based tools, in the form of spreadsheets, are used to monitorthe implementation of the new methodology and to report theprofitability of the standard and custom designs.

A product configuration computer program is used in order to determinewhether a customer specification can be satisfied by a standard productconfiguration, and if not, to warn a sales engineer of a penaltyassociated with the required custom design and assembly, and to indicatewhy the specification could not be met by a standard productconfiguration. If the customer specification can be satisfied by astandard product configuration, then the product configuration programautomatically generates a standard product configuration to meet thecustomer specification, including an assembly drawing and a bill ofmaterials for the specific item to be manufactured. Preferably, theproduct configuration program provides a link between a product selectorand a materials management (MRP) system, in order to automate theprocess of entering orders, designing the standard product, orderingparts, and scheduling assembly of the standard product.

BRIEF DESCRIPTION OF THE DRAWINGS

Other objects and advantages of the invention will become apparent uponreading the following detailed description with reference to theaccompanying drawings wherein:

FIG. 1 is a general flowchart of a product line re-engineering cycleinvolving a product that is assembled to satisfy individual customerorders;

FIG. 2 is a schematic diagram of a specific example of a switchboard;

FIG. 3 is a detailed view of a lower horizontal bus 131 in a firstsection of the switchboard of FIG. 2;

FIG. 4 is a histogram of the frequency and assembly hours for 44possible switchboard configurations for sales of about 240 customswitchboards over a period of time;

FIG. 5 is a sample graph of the relative price level versus the time indays from the time that an order is taken to the time that theswitchboard is to be delivered;

FIG. 6 is a flowchart of the design process flow for sales andmanufacturing of standard and custom switchboards;

FIG. 7 is shown a flow chart of management tasks for implementing thenew sales and manufacturing process flow of FIG. 6.

FIG. 8 is a print-out from a spread-sheet software tool used to managethe implementation of the design process flow of FIG. 6;

FIG. 9 is a schematic diagram of a layout for a switchboard fabricationplant optimized for assembly and quick delivery of standard switchboardsand for assembly of custom switchboards using as many standardcomponents as possible;

FIG. 10 is a block diagram of a digital computer system forautomatically designing a standard switchboard in accordance withcustomer specifications;

FIG. 11 is a flow diagram showing the use of a switchboard configurationmodule introduced in FIG. 10 for producing a quotation for a standardswitchboard;

FIG. 12 is a flow diagram showing the use of the switchboardconfiguration module of FIG. 10 for producing an order includingmanufacturing instructions for a standard switchboard;

FIG. 13A is a first portion of a flowchart of the switchboardconfiguration module of FIG. 10;

FIG. 13B is a second portion of the flowchart begun in FIG. 13A;

FIG. 14 is an elevation view of a mounting pad for a standardswitchboard shown in FIGS. 16 to 19;

FIG. 15 is a floor plan for the standard switchboard shown in FIGS. 16to 19;

FIG. 16 is a left side view of the standard switchboard shown in FIGS.16 to 19;

FIG. 17 is a front elevation of the standard switchboard shown in FIGS.16 to 19;

FIG. 18 is a top view showing available conduit area in the standardswitchboard shown in FIGS. 16 to 19;

FIG. 19 is a top view of the standard switchboard shown in FIGS. 16 to19;

FIG. 20 is a top half of a wiring diagram for the standard switchboardshown in FIGS. 16 to 19;

FIG. 21 is a bottom half of the wiring diagram begun in FIG. 20;

FIG. 22 is a front elevation of a full-height switchboard section havinga full-height utility compartment and a top feed;

FIG. 23 is a front elevation of a full-height switchboard section havinga full-height utility compartment and a bottom feed;

FIG. 24 is a front elevation of a full-height switchboard section havinga full-height auxiliary compartment that does not include a power meter;

FIG. 25 is a front elevation of a full-height switchboard section havinga full-height auxiliary compartment that includes a power meter;

FIG. 26 is a front elevation of a full-height switchboard section havingan upper utility compartment and a lower main protection compartment;

FIG. 27 is a front elevation of a full-height switchboard section havinga lower utility compartment and an upper main protection compartment;

FIG. 28 is a front elevation of a full-height switchboard section havingindividually mounted type P-frame main circuit breakers;

FIG. 29 is a front elevation of a full-height switchboard section havingindividually mounted type SE-frame main circuit breakers;

FIG. 30 is a front elevation of a full-height switchboard section havinga bottom feed and an individually-mounted bolted pressure switch formain protection;

FIG. 31 is a front elevation of full-height switchboard section having atop feed and an individually-mounted bolted pressure switch for mainprotection;

FIG. 32 is a front elevation of a full-height switchboard section havingstacked multiple main circuit breakers;

FIG. 33 is a front elevation of a full-height switchboard section havingstacked multiple main fusible pressure switches;

FIG. 34 is a front elevation of a full-height switchboard distributionsection with I-LINE® circuit breakers from Square D and a bottom feed;

FIG. 35 is a front elevation of a full-height switchboard distributionsection with I-LINE® circuit breakers from Square D and a top feed;

FIG. 36 is a front elevation of a full-height switchboard distributionsection having main lug fusible distribution and a bottom feed;

FIG. 37 is a front elevation of a full-height switchboard distributionsection having main lug fusible distribution and a top feed;

FIG. 38 is a front elevation of a full-height switchboard distributionsection having a lower main lug compartment and an upper compartment fora double row of I-LINE® distribution circuit breakers;

FIG. 39 is a front elevation of a full-height switchboard section havingan upper main lug compartment and a lower compartment for a double rowof I-LINE® distribution circuit breakers;

FIG. 40 is a front elevation of a full-height switchboard section havinga lower main lug compartment and an upper compartment for a single rowof I-LINE® distribution circuit breakers;

FIG. 41 is a front elevation of a full-height switchboard section havingan upper main lug compartment and a lower compartment for a single rowof I-LINE® distribution circuit breakers;

FIG. 42 is a front elevation of a full-height switchboard section havinga lower main lug compartment and an upper compartment for fusibledistribution;

FIG. 43 is a front elevation of a full-height switchboard section havingan upper main lug compartment and a lower compartment for fusibledistribution;

FIG. 44 is a front elevation of a full-height switchboard section havinga lower main circuit breaker compartment and an upper compartment fortwo rows of I-LINE® distribution breakers;

FIG. 45 is a front elevation of a full-height switchboard section havingan upper main circuit breaker compartment and a lower compartment fortwo rows of I-LINE® distribution breakers;

FIG. 46 is a front elevation of a full-height switchboard section havinga lower main circuit breaker compartment and an upper compartment for asingle row of I-LINE® distribution breakers;

FIG. 47 is a front elevation of a full-height switchboard section havingan upper main circuit breaker compartment and a lower compartment for asingle row of I-LINE® distribution breakers;

FIG. 48 is a front elevation of a full-height switchboard section havinga full-height compartment including a single row of I-LINE® distributionbreakers;

FIG. 49 is a front elevation of a full-height switchboard section havinga full-height compartment including two rows of I-LINE® distributionbreakers powered by a 2000 Amp. internal vertical bus;

FIG. 50 is a front elevation of a full-height switchboard section havinga full-height compartment including two rows of I-LINE® distributionbreakers powered by a 3000 Amp. or 4000 Amp. internal vertical bus;

FIG. 51 is a front elevation of a full-height switchboard section havinga lower fusible main switch compartment and an upper compartment for tworows of I-LINE® distribution breakers;

FIG. 52 is a front elevation of a full-height switchboard section havingan upper fusible main switch compartment and a lower compartment for tworows of I-LINE® distribution breakers;

FIG. 53 is a front elevation of a full-height switchboard section havinga lower fusible main switch compartment and an upper compartment for asingle row of I-LINE® distribution breakers;

FIG. 54 is a front elevation of a full-height switchboard section havingan upper fusible main switch compartment and a lower compartment for asingle row of I-LINE® distribution breakers;

FIG. 55 is a front elevation of a full-height switchboard section havinga lower compartment for a 2000 Amp. max. fusible main switch and anupper compartment for distribution fuses;

FIG. 56 is a front elevation of a full-height switchboard section havingan upper compartment for a 2000 Amp. max fusible main switch and a lowercompartment for distribution fuses;

FIG. 57 is a front elevation of a full-height switchboard section havinga lower compartment for an 800 Amp. max. fusible main switch and anupper compartment for distribution fuses;

FIG. 58 is a front elevation of a full-height switchboard section havingan upper compartment for an 800 Amp. max. fusible main switch and alower compartment for distribution fuses;

FIG. 59 is a front elevation of a full-height switchboard section havinga full-height compartment for fusible distribution from an internal 2000Amp. vertical bus; and

FIG. 60 is a front elevation of a full-height switchboard section havinga full-height compartment for fusible distribution from an internal 3000Amp. vertical bus.

While the invention is susceptible to various modifications andalternative forms, a specific embodiment thereof has been shown in thedrawings and will be described in detail. It should be understood,however, that it is not intended to limit the invention to theparticular form shown, but on the contrary, the intention is to coverall modifications, equivalents, and alternatives falling within thescope of the invention as defined by the appended claims.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1 of the drawings, there is shown a general flowchartof a product line re-engineering cycle involving a product that isassembled to satisfy individual customer orders. This re-engineeringprocess has been found to be especially useful for enhancing customersatisfaction and profitability in the manufacture and sale ofswitchboards, and as will be further discussed below, it should also beapplicable to other products, such as other electrical equipment, thathave had a relatively high degree of complexity in the manufacture andassembly process in comparison to customer needs for the products. Anoverview of the entire re-engineering cycle will be presented as itapplies generally to any product line, and then the re-engineering cyclewill be described in detail as it has been applied to switchboards.

In a first step 101, management conducts an in-depth review of theproduct line, including a study of the product offerings, a study of themanner in which the product is manufactured and sold, and extensivecustomer interviews to obtain information on the customers' actual needsthat should be satisfied by the product. Next, in step 102, the resultsof the management review and customer interviews are used to identifyand understand the actual needs of individual customers beyond what thecustomers indicate in the product specifications from the customers, andthis identification and understanding of the actual needs of individualcustomers is extrapolated to identify actual needs of groupings ofcustomers. This is done because in a mature product line, the process ofproduction and sales cannot be substantially streamlined beginning withexisting forms of customer specifications. During maturation of aproduct line, an inherent process of product evolution and gradual,incremental improvements will tend to streamline the process ofproduction and sales from the existing forms of customer specifications.However, in many cases, this process of product line maturation will notlead to a simplification of the customer specifications, due to adivergence between what the customer actually needs and what thecustomer will ask for when attempting to express the needs in the formof a customer specification. Instead, the forms of customerspecifications tend to become much more complex than necessary to definethe customers' actual needs.

Nor is the problem of specification complexity solved by attempting tosatisfy individually the actual needs of each customer. Custom design isthe traditional way of satisfying individually the actual needs of eachcustomer, but custom design is very costly. Instead, the problem can besolved by recognizing that it is possible to more economically satisfyactual needs of defined groups of customers when the individualcustomers have actual needs beyond those indicated in the customerspecifications. Moreover, information obtained from the customerinterviews about the actual needs of each customer may not appearimportant to each customer, but when the information is compiled withsimilar information from the other customers, there will emerge apattern of general customer needs beyond those expressed in the customerspecifications, and those general customer needs can be satisfied byless complexity and cost in a revised sales and production process. Itis expected that this should be the case in the electrical equipmentindustry, where custom design has been a traditional way of satisfyingindividual customer needs, where established product lines tend to beeither 100% custom products or 100% standard products, and wherecustomer specifications are often provided by consulting engineers whoare concerned with product safety and tend to over-engineer in case ofdoubt or lack of time to investigate all available options or specificcircumstances of a particular job.

Next, in step 103, management revises the product specifications to moreprecisely correspond to the actual needs of the groupings of customersthat were identified in the previous step 102. Then, in step 104, theexisting product configurations, modules, components, and parts areevaluated in view of the revised specifications. This evaluation is doneto determine whether some of the existing product configurations,modules, components, and parts are no longer needed, to determinewhether to design entirely new product configurations, modules,components, and parts to better satisfy the customers' actual needs, andthen to organize and rank the product configurations, modules,components, and parts on a scale of those that are most likely to beused to satisfy the customers' actual needs to those that are leastlikely to be used to satisfy the customers' actual needs.

In step 105, management identifies a subset of the productconfigurations, modules, components, and parts that in variouscombinations satisfy a majority (typically about 80%) of the customerneeds. The specific percentage is selected to balance the increased costof custom design (for a lower percentage) verses the increased cost ofmaintaining additional standard modules, components, and parts (for ahigher percentage).

In step 106, management standardizes and streamlines a process ofordering and manufacturing standard designs using the standardconfigurations, modules, components, and parts. In other words, a firststep in order taking and processing is to determine whether or not thedesired product specifications can be met using any of the standardconfigurations, modules, components, and parts. If so, then the orderfor the standard product is entered into a materials handling andproduct manufacturing process in which the plant layout and assemblyprocess is optimized for assembly and quick delivery of the standardproduct that will meet the desired product specifications. If not, thenthe desired product specifications must be satisfied by a custom design.

In step 107, management revises the process of custom design andmanufacture of non-standard configurations to maximize use of thestandard modules, components, and parts.

The re-engineering cycle of FIG. 1 has been found to be especiallyuseful for the re-engineering of the order processing, design, andmanufacture of switchboards. A schematic diagram of a specific exampleof a switchboard is shown in FIG. 2. The switchboard includes twoswitchboard sections generally designated 111 and 112. Each of theswitchboard sections 111 and 112 includes a rectangular metal box havingdimensions of 36" wide by 90" high by 24" deep.

The switchboard section 111 is a combination 1/2 height hot sequenceutility and 1/2 height main fuse, with a top feed and lower rightthrough bus and lugs. In particular, the switchboard section 111receives three-phase (φ₁, φ₂, φ₃) power from power lines 113 enteringenclosure of the section 111 from the top. The power lines 113 areelectrically connected inside the enclosure to respective horizontalbusses 114, 115, 116, 117 that span vertical dielectric mounting bars118, 119. The vertical dielectric mounting bars 118, 119 are secured tothe rear of the enclosure of the switchboard section 111 and extend fromthe bottom to the top of the switchboard section 111. Three-phasecurrent from the power lines 113 is conveyed by bus bar sections (notshown in FIG. 2; see FIG. 3 and the corresponding description below) toa mains switch 120 mounted near the front face of the switchboardsection 111 and having an external actuator handle 121 in front of theenclosure of the switchboard section 111. Power flowing from the powerlines 113 to the mains switch 120 is metered by a utility meter 122having a front face mounted on the front of the switchboard section 111.When the switch 120 is in a closed state, three-phase current flows fromthe power lines 113 through the switch 120 to a set of main fuses (notshown) in a fuse module 123. The three-phase current flows through thefuses in the fuse module 123 to through-bus connections 124, 125, 126,and a neutral through-bus connection 127 from the switchboard section111 to the switchboard section 112. The through-bus connections 124,125, 126, 127 extend from respective horizontal busses 128, 129, 130,131 in the switchboard section 111 to respective vertical busses 132,133, 134, 135, in the switchboard section 112.

The switchboard section 112 is a full-height distribution circuitbreaker section having an array of circuit breakers 136 mounted near thefront of the section 112 and extending from about the top to about thebottom of the section 112. Each circuit breaker receives power from atleast two of the vertical busses 132, 133, 134 conveying power, andsupplies power to a respective distribution circuit. For clarity, onlythe distribution lines 137 from a first circuit breaker 138 and thedistribution lines 139 from a second circuit breaker 140 are shown inFIG. 2.

Numerous parts have been omitted from FIG. 2 for clarity. These partsinclude lugs and interconnection busses which provide the circuit pathsbetween the various power lines, busses, modules, and components shownin FIG. 2. These parts introduce a good deal of complexity in the designand manufacture of the switchboard. For example, FIG. 3 shows a detailedview of the lower horizontal bus 131 in the first switchboard section(111 of FIG. 1). The bus 131 includes four co-extensive parallel-spacedbus bars 151, 152, 153, and 154 made of copper or aluminum. As shown inFIG. 3, the left-most end portions of the bus bars 151, 152, 153, and154 are clamped to the dielectric bar 118 by a bolt 155.

Electrical connections between the bus 131 and modules or components(such as the fuse module 123 in FIG. 2) are made by various parts thatcomprise interconnecting bus sections such as the bus section 157 andthe bus section 158. The bus sections 157, 158 are each comprised ofthree co-extensive, parallel-spaced flat bars of copper or aluminum. Thebus section 157 is comprised of angle-shaped bars 161, 162, 163 securedto the bus 131 by a bolt 164. The bus section 158 is comprised ofelongated bars 165, 166, 167. The bus section 158 is joined to the bussection 157 by four bolts 168, 169, 170, 171.

In order to fix the relative position of the bus section 158 within theenclosure of the switchboard section (111 in FIG. 2) containing the bussection 158, the bus section 158 is mounted by dielectric spacers 176 onan a metal rod 172 covered by a tubular dielectric sleeve 173 andextending from a side rail 174. The side rail 174 is mounted parallel tothe dielectric bar 118 within the enclosure of the switchboard section(111 in FIG. 2). The metal rod 172 has a threaded end portion secured tothe side rail 174 by a nut 175.

It should be apparent that the construction shown in FIG. 3 permits thebus sections 157 and 158 to be mounted at various lateral positionsalong horizontal bus 131. For example, the bolt 164 can be loosened topermit the bus section 157 to slide laterally along the horizontal bus131, and the lateral position of the bus section 158 can be selected bychoosing the number of dielectric spacers 176 disposed between the siderail 174 and the bus section 158. In this fashion, parts similar to theparts in the bus sections 157 and 158 can be used to electricallyconnect electrical terminals and lugs of the various modules andcomponents in the switchboard sections (111, 112 in FIG. 2) to therespective horizontal and vertical busses in the switchboard sections.Parts similar to the parts in the bus sections 157 and 158 can also beused for electrical connections between the various modules andcomponents of the switchboard sections. The precise length and shape ofthe parts, however, will be dictated by the configuration and relativeorientations of the modules and components of the switchboard sections.The number of flat bars included in each bus section should also varydepending on the desired ampacity; for example, four flat bars are usedfor 4000 Amp., three flat bars are used for 3000 Amp., and two flat barsare used for up to 2000 Amp. Therefore, a large number of differentparts are needed for manufacturing switchboards of variousconfigurations.

The present invention is the result of an exhaustive, multi-faceted andin-depth review at the Square D Company of the switchboard business. Thereview extended over a wide spectrum of business activities beginningwith assessment of customer requirements and leading to delivery of asatisfactory product. The review confirmed that the existing process ofproducing and selling switchboards to meet customer-suppliedspecifications was efficient and could not be improved significantly.However, the review did not end with an analysis of the company'sinternal operations such as the role played by the order engineer, thecomputer-based tools, the component and product offerings, and thematerial resource management and assembly operations. Instead, thereview was extended to include a detailed evaluation of the variedbusiness needs of customers by various means including comprehensiveinterviews of customers. The customers included various local utilitiesthat set certain specifications for the switchboards used in their powerdistribution networks.

The detailed evaluation revealed a discrepancy between the actual needsof the customers and the needs that were perceived by the customers andexpressed in the customer specifications for switchboards being ordered.Tens of customers in strategic business segments and markets wereinterviewed in the first month of the interviews. The customers wereasked how they were purchasing and installing their switchboard, andthey were probed as to why they had submitted any customerspecifications that were inconsistent with their actual needs. In somecases there was a discrepancy between the customer specifications andthe customer's actual needs because the customer was simplyre-submitting a prior specification from a previous order which, inturn, had not been optimized either. The customer thought that the priorspecification would be adequate for the present needs, but the customerdid not have a convenient basis for considering that a lower price couldbe obtained if the specification were revised to more accurately reflectthe present needs.

The customer specifications were much more complex than the customerneeds. Due to the complex customer specifications, the order engineerhad a difficult task of designing a switchboard that would comply withthe customer specifications. The difficulty could not be reduced simplyby better communication between the customer and the order engineer, orby more complete knowledge of the product offerings of the switchboardproducer.

As a result of the customer interviews, the internal operations ofSquare D Co. were analyzed in terms of the complexity introduced bydesigning and assembling switchboards in response to customerspecifications. The complexity was quantified and expressed by ahistogram or graph of the frequency of assembly hours for an ensemble ofabout three-thousand of the custom-engineered switchboards.

Shown in FIG. 4, for example, is such a histogram over a representativeperiod of time during which about 240 custom switchboards were sold.Each data point in FIG. 4 represents the frequency and assembly hoursfor one of 44 possible classes of switchboard configurationsmanufactured and sold by Square D Co. before implementation of thestandard switchboard sections, modules, components, and parts asdescribed below. The frequency associated with each data point is thenumber of occurrences of sales in the ensemble. For example, the datapoint 181 represents 26 sales over the sample period of Square D Co.I-LINE® switchboard sections having a busway connection, any custom bussubstation connection, or any non-EU service utility. The data point 182represents 14 sales of Square D Co. 3000/4000 Amp. SEF or 3000 Amp. SEDswitchboard sections having a busway connection, substation Aconnection, non-EU service utility, a custom bus, or any wiring. Thedata point 183 represents 8 sales of Square D Co. BP20 branchcircuit-breaker switchboard sections having a busway connection,substation A connection, or non-EU service utility, any custom bus, orany wiring. The data point 184 represents 5 sales of Square D Co.switchboard sections having all special breakers or switches MP, DS,4000 Amp. SED, and vendor purchased. A good number of the data pointsrepresent possible switchboard configurations that had no sales in theensemble. A few other data points have a frequency of one or two, andtherefore represent infrequent occurrences of sales during the sampleperiod.

The histogram, called a Schedule Matrix, extended over a surprisinglywide range of complexity, as indicated by the wide range of assemblylabor hours required to manufacture the switchboards. (Excluded from theassembly labor hours are the engineering hours associated with thecustom design of the switchboards.) In contrast, the customer interviewssuggested that relatively few customers needed the more complex andcostly switchboard designs. The histogram further suggested that somecustomers were paying for complexity that they did not need, and weresubsidizing the relatively few customers that needed the complexity.More importantly, the Schedule Matrix identified the switchboardconfigurations that were the least complex and the switchboardconfigurations that were the most complex, and identified theswitchboard configurations that were the most frequent and theswitchboard configurations that were the least frequent.

Due to the potential for increased margins revealed by the ScheduleMatrix and the customer interviews, further investigation and analysiswas directed to quantifying the actual customer needs and identifyingspecific switchboard configurations that could satisfy the most frequentcustomer needs. Customer needs were classified in terms of site specificneeds, area specific needs that had to be complied with regardless ofwhether the customer would specify them, and general needs as revealedby the customer interviews.

Site specific needs are the needs determined by the specific building inwhich the switchboard is to be installed. Absent an error, the presentsite specific needs should be accurately specified by the architect of abuilding under construction. However, the site specific needs includedin a customer specification may include a need to meet an expectedfuture need. A knowledge of the switchboard product offering may help inthe specification of a need to meet expected future needs at areasonable cost. For example, if an existing switchboard does not havethe space for accommodating components that could be added to increasecapacity for a future need, then that future need might have to besatisfied by a possibly more expensive alternative of installing anadditional switchboard in the future to accommodate the additionalcomponents.

Area specific needs include local codes and standards, and local utilityrequirements. The switchboard supplier should know the intended site ofa switchboard, and avoid the assembly of a switchboard that cannotpossibly comply with a local code or standard or local utilityrequirement at the intended site.

Considerable effort was devoted to negotiating with the local utilitiesfor approval of new standard designs and variances of requirements thatwould otherwise require custom design. Negotiation was conducted withutilities in an attempt to further standardize requirements for utilitycompartment isolation, compartment window requirements, compartmentbrackets, bus bar type and spacing for connection to the compartment,utility compartment sealing means, potential tap connection and mountingrequirements, insulating barriers, and approval of ground faultprotection devices. For example, some local utility requirementsprohibit any electrical power take-off connections from being made aheadof the mains disconnection device. This requirement is intended toaddress the safety concern of creating an electrical shock hazard when ahuman operator would otherwise believe that power has been disconnectedby manually opening the mains disconnection device. However, thisrequirement interferes with a mains disconnection device havingautomatic ground fault protection. When a mains disconnection device hasautomatic ground fault protection, it is desirable to provide a pilotlight powered from a take-off connection ahead of the mainsdisconnection device so as to indicate to the operator that the mainprotection device opened due to ground fault. Without this indication,an operator might reclose the main into a possible faulted conditionbefore trying to determine the cause of the faulted condition and takingcorrective action. A variance has been granted for this situation whenall exposed, live parts ahead of the main disconnection device arebarriered and warning labels are present.

General customer needs included the occasional need for immediatedelivery, the customer demand or willingness to pay for short lead-time,and the ability to satisfy most customer needs with a limited number ofbasic switchboard configurations. Such general customer needs werequantified by analysis of customer records of about 1,000 past ordersand requests for special service.

The need for immediate delivery occasionally resulted from an erroneouscustomer specification of a site-specific need, when it is found that aswitchboard delivered to the building site cannot be installed becauseit will not satisfy the actual site-specific need. Because delay ininstallation may delay completion of construction or use of thebuilding, the need for an immediate replacement switchboard may be veryacute. The need for immediate delivery may also result from destructionor serious damage to a switchboard at the building site or duringdelivery of a switchboard to the building site.

Customers may be more or less willing to pay for short lead timedepending on the amount of time between the placement of an order andthe time that the switchboard should be installed according to aconstruction schedule. If a building contractor discovers that an orderhas not been placed or was erroneous shortly before the time that theswitchboard is to be installed, then the contractor may be very willingto pay for a short lead-time in order to avoid a penalty forconstruction delays.

The ability to satisfy most customer needs with a limited number ofbasic switchboard configurations was a rather complex task. It involvedidentifying the more frequent and less complex switchboardconfigurations expressed by the Schedule Matrix, grouping the morefrequent and less complex switchboard configurations in terms ofstandard configuration classes, and deciding how many of the standardconfiguration classes should be supported as standard productassemblies. If a customer's actual needs could not be satisfied with aswitchboard assembled from a standard configuration class, then thecustomer's actual needs would be satisfied by custom design and assemblyof a switchboard. However, the Schedule Matrix was not the sole sourceof information for standardizing the more frequent and less complexswitchboard configurations, since the Schedule Matrix only expressed thecustomer needs as perceived by the customers and expressed in thecustomer specifications. Instead, the more frequent and less complexswitchboard configurations were also standardized with an understandingof area-specific needs, and an understanding of how components can bephysically assembled to make switchboards that will satisfy thecustomer's actual needs. Classes of switchboard sections of functionalequivalence were identified. Switchboard sections within a class offunctional equivalence were interchangeable but not identical. Most ofthe switchboard sections could be freely combined to form a switchboard.Each class of switchboard sections provided one of three majorswitchboard functions: utility metering, main devices, and branch ordistribution breakers. It was estimated that the actual needs of atleast 80% of the customers should be satisfied using 300 standardswitchboard sections, and the 300 switchboard sections could beorganized into nineteen classes. The remaining customers would getcustom-designed switchboards. The 80% figure resulted from a heuristicprocess. Below about 75% there would be too much custom design, andabove about 85% there would be too many classes and standard sectionsand associated investment in manufacturing capabilities.

The desired percentage figure in the general case would depend onbusiness reasons, such as the customer demand for custom features, thecost of custom design and production, and the cost of supportingadditional standard product designs in the standard design andproduction process. In any case, the percentage figure that will beobtained in practice can be adjusted upward or downward by includingmore or less groupings of customers, and their corresponding standardproduct designs, in the standard design and production process or in thecustom design and production process.

The nineteen standard switchboard classes were the following:

1) full height empty section;

2) full height utility hot sequence (meter is always hot and main devicefollows);

3) full height utility cold sequence (meter follows main device);

4) full height empty section with through bus and lugs;

5) full height main circuit breakers;

6) full height main fuses;

7) full height distribution breakers 2,000 Amps.;

8) full height distribution breakers 3,000 Amps.;

9) full height distribution fuses;

10) combination half height main circuit breakers and half height maincircuit breakers;

11) combination half height main fuses and half height main fuses;

12) combination half height main circuit breakers and half heightdistribution breakers;

13) combination half height main fuses and half height distributionbreakers;

14) combination half height main circuit breakers and half heightdistribution fuses;

15) combination half height main fuses and half height distributionfuses;

16) combination half height utility (hot sequence) and half height maincircuit breakers;

17) combination half height utility (hot sequence) and half height mainfuses;

18) combination half height utility (cold sequence) and half height maincircuit breakers;

19) combination half height utility (cold sequence) and half height mainfuses.

The full and half-height utility, main, and distribution circuits inthese nineteen standard switchboard configuration classes themselves arecomprised of standard parts and have a limited range of attributes.Major components used in the standard switchboards, such as utilitycompartments, were themselves standardized, which involved reducing thenumber of such standard components and modifying the standard componentsto have a wider range of applicability. A standard switchboard, forexample, will have a continuous current capacity of no more than 4000Amps, a maximum voltage rating of 480 Vac, a short circuit currentrating (SCCR) of no more than 200 kA, and an aluminum or copper bus. Themetal box of a standard switchboard can be a NEMA type 1 enclosure or aNEMA type 3R non-walk-in enclosure. A standard switchboard can havefixed individually mounted mains with thermal magnetic (M or P)breakers, micrologic (M, P, or SE) breakers, or fusible (BP) protection;fixed individually mounted (M, P or BP) feeders; and group mounted mainsor feeders with thermal magnetic (F, K, L, M, or N) breakers, micrologic(L, M, or N) breakers, or fusible (QMJ or QMB) protection. Wherepermitted by utility and local codes, a standard switchboard can haveauxiliary switches (1A and 1B), a 120 Vac shunt trip, short time andground fault (GF pit) protection, trip indicators or a local currentammeter, a power meter, a circuit monitor, a pull box, or an auxiliarysection. It now appears that these nineteen standard switchboardconfiguration classes and the use of standard components can satisfy atleast 80% of the customer orders.

Switchboards for automatic power transfer systems are examples ofswitchboards that cannot be designed from the standard switchboardconfiguration classes. For a highly critical power application, forexample in a hospital, there is an on-site back-up generator. If theutility power supply fails, then the back-up generator startsautomatically, the utility lines are switched out, and the back-upgenerator is switched into the building power distribution circuits. Amicroprocessor is programmed to monitor the power fed to thedistribution circuits and the voltage of the utility lines and theback-up generator, and the microprocessor automatically decides when toswitch over between the utility lines and the back-up generator. Suchautomatic transfer systems are highly complex and typically very sitespecific.

The selection of the set of standard switchboard configuration classeswill in effect redefine the Schedule Matrix and the cost and lead-timefor supplying a configuration that is required to satisfy a customer'sactual needs. Although a basic objective was to reduce the cost andlead-time associated with any order that could be satisfied, there isalso an advantage that the shape of the redefined Schedule Matrix willmore closely match the histogram of the customer's actual need forcomplexity. In order to make pricing decisions, estimates of value andcost were made for everything provided to the customer, including theswitchboard product and related components installed or likely to beinstalled in the switchboard, timeliness of delivery of the product,drawings and documentation, service, and spare parts. The pricing chosenfor the various possible switchboard configurations was more fairlybased on the actual customer demand for each possible switchboardconfiguration and the cost of supplying each possible switchboardconfiguration. This pricing scheme for the various possible switchboardconfigurations is an effective mechanism for customers to re-evaluatewhat their actual needs are on the basis of both the perceived value andthe associated cost for such needs.

FIG. 5, for example, shows a sample graph of the relative price levelversus the time in days from the time that an order is taken to the timethat the switchboard is to be delivered. The relative price levelfunction corresponds to the premium that an average customer should bequoted for quick delivery time. The relative price level is set by twocharacteristic parameters. The first parameter is the value of thepremium for a one-day delivery time. A one-day delivery time is theminimum guaranteed delivery time for a standard switchboard. A value ofthree is an approximation of what an average customer should be willingto pay without detriment to the customer relationship. The secondparameter is the minimum delivery time for which there should be nopremium. This parameter is set by the usual delivery time in theindustry. A value of twenty days represents a delivery time that thecompetition would supply without a premium. In practice, mostswitchboard sales are negotiated based on the present circumstances ofthe customer, the supplier, and the competition, so that the relativeprice level function for quick delivery is only one of a number offactors considered by a sales engineer when formulating a pricequotation for a switchboard. In general, each market may have adifferent relative price level function.

Once the new production and sales methodology has been rolled out to allsales regions and in use for about six months, statistics regardingon-time delivery will be used to establish a delivery guarantee similarto that now used by express package delivery services. If a customswitchboard is not delivered by the customer-specified "on-site date,"then the customer will get a credit for each day after the "on-site"date until the switchboard is delivered. The delivery statistics will beused to set the amount of the credit to ensure a reasonable cost for thedelivery guarantee.

It was decided that manufacturing and inventory control for standardswitchboards would be separated from manufacturing and inventory controlfor custom switchboards. The order processing, manufacturing, andinventory control for standard switchboards would be fully automated andgiven priority over custom switchboards. The plant layout and assemblyprocess would be optimized for production of the standard switchboards.The resulting design process flow is shown in FIG. 6.

In the first step 191, a sales engineer works with a customer tonegotiate a quote. The sales engineer can use conventional tools such asa product catalog and order forms, or the sale engineer can usecomputer-based tools such as a product selector. Then in step 192 thequote is analyzed automatically, using a computer-based tool.

If the analysis in step 192 indicates that the quote is not for astandard product, then the process flow branches from step 193 to step194 to the start of a conventional order processing flow. In step 194,the order is checked, clarified, classified, and approved for furtherprocessing. Then in step 195, the order is scheduled for engineeringapproval. In step 196, an order engineer determines whether or not aproduct in conformance with the order can be manufactured. The orderengineer either approves the order as it is, or modifies the order forapproval. In step 197, the customer approves any modifications to theorder. In step 198, the order is scheduled for manufacture. In step 199,any custom parts are engineered. In step 200, the custom parts areordered or manufactured. In step 201, the custom product ismanufactured.

If in step 193 the automatic analysis of the order determines that theproduct is standard, then execution continues to step 202. In step 202,a bill of materials is generated automatically. In step 203, the orderis scheduled automatically for just-in-time manufacture and delivery. Instep 204 the required standard parts are obtained from inventory, and instep 205 the standard product is assembled from the standard parts.

Referring now to FIG. 7, there is shown a flow chart of the managementtasks that were performed at Square D Co. in order to implement the newsales and manufacturing process flow of FIG. 6. In the first step 211 ofFIG. 7, management established a detailed sales office and manufacturingplant roll-out schedule for implementation of the new switchboard salesand production methodology. Since four manufacturing plants and about150 sales offices were involved, management recognized that the salesoffices and manufacturing plants should not be switched over all at onceto the new methodology. Instead, the sales offices and manufacturingplants were grouped by geographic region related to utility and localcodes, and the geographic regions were switched over one-by-one in asequence, starting with the regions that would offer the most costsavings in the least amount of time. The roll-out at each region wassubdivided into adaptation, installation, training, and implementationstages, and was spread out over the sales offices in each region.

In step 212, management established a design engineering master schedulethat would plan the changes in the engineering design center proceduresnecessary to support the sales office and manufacturing plant roll-outschedule. The required engineering design activities were identified andgrouped into project stages, each stage being two to three months induration to facilitate day-to-day management of the engineering designcenters.

In step 213, management developed and implemented weekly progressmanagement tools to monitor progress and allocate resources asappropriate for implementing the roll-out schedule. Challengesappropriate for each region were identified and tools and procedureswere adapted to meet those challenges. For example, for each region thestandardized utility compartment of the switchboard had to be approvedfor compliance with the utility and local codes. Weekly progressmanagement tools in the form of spread sheets were developed andimplemented to monitor progress and allocate resources as appropriate.

An example of such a spread sheet is shown in FIG. 8, which indicatesthe switchboard project status as of Jun. 6, 1997. A right-most columnfor comments in this spreadsheet has been omitted because thespreadsheet would otherwise be too large to show in one figure. Acomment associated with a row or sub-project in the spreadsheet mayindicate the activity currently being done for the sub-project. Forexample, a comment associated with the sub-project "SW 164 PublicService E & G" would be: "2K UCT assys complete, 3K parts complete, 3Kassys 95% complete, 4K layouts continuing." For the sub-project thathave been 100% completed, the comment would say: "All records to RecordsGroup."

Returning to FIG. 7, in step 214, management prepared for a one-daymanufacturing cycle for the production of standard switchboards. Forexample, if the customer needed a standard switchboard in twenty-fivedays, then assembly of the switchboard would be begun in twenty-fourdays for a just-in-time delivery to the customer. Sufficient plantcapacity was provided to serve all important customers. The plantcapacity was managed for flexible output. The manufacturing processesfor the standard switchboards were maintained completely separate fromthe manufacturing processes for the complex, custom-designedswitchboards. Cataloging of the custom switchboard designs would bedesirable and will be implemented soon. For leverage, engineeringresources were all relocated to the manufacturing plants. As needed, theengineers were focused on customer issues for order engineering, onproduct issues for design engineering, or on manufacturing issues formanufacturing engineering.

Referring to FIG. 9, there is shown a diagram of the plant layoutoptimized for assembly and quick delivery of the standard switchboards.The floor space of the switchboard fabrication plant 501 is dividedalmost equally into an assembly line 502 and a custom assembly area 503.Although only about 20% of the switchboards ever enter the customassembly area 503, the custom assembly area has about the same floorspace as the assembly line 502 because the switchboards move through thecustom assembly area about four times slower than they move through theassembly line 502. For example, standard switchboards will pass throughthe assembly line 502 in about a few hours to no more than one day, butcustom switchboards will pass through the custom assembly area 503 in afew hours to a few days and up to a week or more.

The assembly line 502 has six stations, including a frame assemblystation 504, a utility compartment installation station 505, a mainsprotection installation station 506, a distribution protectioninstallation station 507, a final inspection station 508, and a shippingstation 509. In the frame assembly station 504, a switchboard frame isassembled for each switchboard in accordance with the switchboardmanufacturing instructions. The frame includes enclosures for one ormore switchboard sections to be included in the standard or customswitchboards. When assembly of the frame is finished, a set of wheelsare snapped onto the back of the frame, the frame is laid on its back,and the frame, in a horizontal orientation, is rolled on down theassembly line.

A standard switchboard frame will be rolled along the assembly line pastor through all of the intermediate installation stations 505, 506, and507 until reaching the final inspection station 508, where the wheelsare taken off. If a utility compartment needs to be installed in theswitchboard, then the frame will stay in the utility compartmentinstallation station 505 for a while, minutes to a couple of hours,until installation of the utility compartment is done. If mainsprotection components need to be installed in the switchboard, then theframe will stay in the mains protection station for minutes to a coupleof hours, until installation of the mains protection components is done.If distribution or branch circuit protection components need to beinstalled in the switchboard, then the frame will stay in thedistribution protection station for minutes to a couple of hours, untilinstallation of the distribution or branch circuit protection componentsis done.

A custom switchboard will also be rolled along the assembly line 502 butmay stay in one or more of the intermediate stations for a shorterperiod of time to install any standard components needed in the customswitchboard, and in the last intermediate station where the last of thestandard components are installed, the custom switchboard will bediverted to the custom assembly area 503 to complete the assembly of thecustom switchboard. Once custom assembly is completed, the customswitchboard passes from the custom assembly area 503 to the finalinspection station 508 of the assembly line 502. For example, if thereare no standard distribution or branch components needed in the customswitchboard but the custom switchboard needs standard utility componentsand standard mains protection components, then the frame for the customswitchboard will pass from the frame assembly station 504 to the utilitycompartment station 505 where the standard utility components areinstalled, and then from the utility compartment station 505 to themains protection installation station 506 where the standard mainsprotection components are installed, and then from the mains protectionstation 506 to the custom assembly area 503, and then from the customassembly area 503 to the final inspection station 508.

In the final inspection station 508, the standard or custom switchboardis tested by applying test voltages to the switchboard busses andmeasuring leakage currents, and also by testing any power monitoring orlogging functions of the switchboard. The same test equipment is usedfor testing custom and standard switchboards, because the test equipmentis relatively expensive and the testing for each switchboard can be donerelatively quickly, in about ten to twenty minutes. Circuit breakersneed not be tested for tripping upon short or overload, because thecircuit breakers are tested individually just after assembly in aseparate circuit breaker manufacturing plant, before being placed intoinventory for assembly into the switchboards.

In the shipping station 509, the completed custom or standardswitchboard is wrapped, labeled, and shipped to the customer-specifieddestination.

The custom assembly area 503 includes a custom wiring station 510 forinstallation of custom wiring, a custom bus station 511 for installationof custom busses, a custom paint station 512 for custom painting, and amiscellaneous custom assembly station 513 for installation of any othercustom modules or components. The standard paint color, used for exampleon the switchboard frame and external enclosure panels, is grey, and inthe custom paint station, any other color (such as green or yellow) ispainted over the standard grey color.

Returning to FIG. 7, in step 215, computer-based tools were developed,tested, and implemented for configuring the standard switchboards andmanaging the standard product manufacturing (in accordance with theprocess flow steps 191, 192, 193, 202, and 203 of FIG. 6). Thesecomputer-based tools will be further described below.

Finally, in step 216, the roll-out schedule was implemented in the salesoffices. A group of product specialists, trainers and productionmanagers traveled among the various regions and among the sales officesin each region to install the new tools, train the sales force and orderengineers, and manage the changes in the switchboard production processfor assembly of the nineteen basic switchboard configurations. Theirprogress was monitored and reported to management by the spread-sheettools. For example, an action plan was implemented at each field office.In general, each action plan had six basic activities, including abetter contractor focus, distributor focus, strategic pricing,capability training, measurements, and employee communication andincentives.

The contractor focus was directed to identifying a group of the "highestpotential" customers. For example, the top 200 customers by potentialrevenue in the region were identified, and out of the top 200, 100customers were identified by considering different factors such as thenumber of engineers on the customer's staff and any indication ofcustomer loyalty. Each Square D Co. sales engineer was assignedexclusive responsibility for ensuring total customer satisfaction of agroup of about a dozen of these most attractive customers.

The distributor focus involved communicating the new sales andproduction methodology and its benefits to all distributors serviced bythe field office. The distributor sales people who would be actuallyselling the standard switchboards were identified, and an education andtraining plan was prepared for the appropriate sales people.

The strategic pricing involved developing a specific relative pricelevel vs. delivery function (e.g., the function discussed above withreference to FIG. 5) for the region serviced by the field office, anddeveloping qualitative guidelines for negotiating bids based on thisfunction. During the introduction of the new switchboard sales andproduction methodology, corporate management reviewed each bid to ensurethat orders would not be lost if the guidelines were followed.

The capability training involved the training of sales engineers to usethe new switchboard sales and production methodology for creating andextracting customer value. This training focused on value engineeringand how to manage customer accounts for total customer satisfaction.

The measurements involved identifying field office specific measurementsand measurements that would be reported only during the introductionphase, in order to supplement the measurement tools that would beapplicable to once the new switchboard sales and production methodologywere installed and fully implemented. After the introduction, managementwill continue to closely monitor the percentage of switchboard orderssupplied by the standard switchboards, and the profitability of thestandard and custom design switchboards.

The employee communication and incentives involved meetings of thecorporate switchboard project representative with individual fieldoffice managers, and a switchboard project implementation board at eachfield office. Management announced that incentives and prizes would beawarded to sales engineers for the first shipment of a standardswitchboard, the highest monthly volume, and the highest monthly pricemultiplier.

Once the standard switchboard classes were determined, a switchboardconfiguration computer program module was designed for the order entrysystem in order to determine whether a customer specification could besatisfied by standard switchboard sections, and if not, to warn thesales engineer of a penalty associated with the required customassembly, and to indicate why the specification could not be met by astandard switchboard. (Once a wider range of the Square D Co. productline has been standardized, it is envisioned that the switchboardconfiguration computer program module will be further programmed tosuggest modifications to the customer specification that would permitthe specifications to be satisfied by standard switchboard sections.) Ifthe customer specification could be satisfied by one of the standardswitchboard configuration classes, then the switchboard configurationmodule generated a specific switchboard design to meet the customerspecifications, including an assembly drawing and bill of materials(sometimes referred to as a BOM) for the specific switchboard design.The switchboard product configuration module can generate about 300switchboard configurations from the nineteen standard configurationclasses.

Referring to FIG. 10, the switchboard configuration program module 225is used in a digital computer system 220 including a data processor 221and a memory 222. The switchboard configuration program module 225 canact as an intermediary between a product selector program 223 and a MRPsystem program 224.

The product selector program 223 is accessed by a sales engineer at acomputer terminal 227 to obtain a quote or to place an order. Theproduct selector program 223 accesses a product database 228, includingquestions and valid answers about products that can be quoted orordered. Specified features or components can either be locked out of aquote or order, or included in a quote or order that is validated. Ifthe specified features or components are valid in a standardswitchboard, the product selector program invokes the switchboardconfiguration program module to design a standard switchboard includingthe specified features or components. This standard switchboard designis the basis for either a quote or a list of components andmanufacturing instructions for an order. The list of components andmanufacturing instructions is passed to the MRP system program 224.

The MRP system program manages an inventory data base 229 and schedulesthe ordering of parts and the timing of manufacturing operations. Thestatus of the parts inventory and the schedule for manufacturingoperations can be reviewed by a MRP manager 230 at a computer terminal231. The digital computer system 220 also is programmed with anorder-to-payment system 232 that manages and automates all order entry,billing, invoicing, and shipping information processing for all standardas well as custom switchboard orders. The digital computer system 220provides seamless integration of the order-to-payment functions with thefunctions of the product selector 223, the switchboard configurationprogram module 225, and the MRP system program 224.

Referring to FIG. 11, the product selector 223 and the switchboardconfiguration module 225 are shown being used to generate a quote. Theproduct selector 223 passes a list of standard features to theswitchboard configuration module 225. The switchboard configurationmodule applies layout and restriction logic to design a standardswitchboard by selecting and arranging a set of compatible modules,components and parts that provide the specified features. The selectedmodules and components are indicated in a descriptive BOM and in amanufacturing BOM. The manufacturing BOM, however, further includesparts used for electrical and mechanical connections between the modulesand components. The switchboard configuration module determines theprice, cost, and delivery time for the switchboard from the cost andavailability of the required modules, components, and parts. Theswitchboard configuration module automatically generates a set ofschematic drawings including various views of the switchboard, a wiringdiagram, and a table including a row of information for each module orcomponent in the switchboard.

The results produced by the switchboard configuration module 225 arepassed back to the product selector and used to prepare a quote 241 forthe manufacture and delivery of a switchboard including the items in thedescriptive BOM. The descriptive BOM is included in the quote to acustomer. Although the corresponding manufacturing BOM typically wouldnot be included in the quote, the switchboard to be delivered for thequoted price would include the additional parts in the manufacturing BOMthat are needed to interconnect the components and modules mentioned inthe descriptive BOM.

Referring to FIG. 12, the product selector 223 and the switchboardconfiguration module 225 are shown being used to generate an order.Initially, the product selector 223 and the switchboard configurationmodule 225 perform the same functions as they performed for generating aquote. The product selector produces an order data report 242 that isvery similar to a quote. However, the switchboard configuration moduleperforms an additional function of invoking an MRP interface program orsubroutine 243 that accesses the MRP system and expands themanufacturing BOM into a component and parts list including all of theindividual items that are inventoried and used up in the manufacture ofthe switchboard. The MRP system uses this component and part list toensure that the items required for the assembly of the switchboard willbe available at the scheduled time of assembly 244.

The switchboard product selector asks the sales engineer a predeterminedseries of questions about a switchboard to be specified during aninteractive session. For example, the sales engineer is asked to specifyampacity, voltage rating, copper or aluminum bus, incoming feeddirection, enclosure type, fuses or breakers for mains and distributionor branch circuits, and types of fuses or breakers. There is a valid setof answers to each question. If the sales engineer does not supply avalid answer to a question, or responds with no answer, the system willsupply the set of valid answers for the question. The sales engineer canrequest further information about each valid answer.

The first question, "Type of Line-up?", can be answered "QED-S", whichinvokes the switchboard configuration module. The switchboardconfiguration module checks that the system ampacity is no more than4000 Amps; if not, then the sales engineer is warned that a standardswitchboard can have no more than 4000 Amps. The switchboardconfiguration module checks that the system voltage is no more than 480Vac; if not, then the sales engineer is warned that a standardswitchboard can handle no more than 480 Vac. In a similar fashion, theswitchboard configuration module checks for the other limitations of astandard switchboard, including any optional features precluded byutility and local codes, and warns the order engineer if a standardswitchboard cannot satisfy the requirements. There is also a consistencycheck of all of the answers, because not all combinations are possibleor meaningful, as will be further described below. The switchboardproduct selector can also process information from a filled-in orderform, which is essentially a list of the same questions and selectedmultiple-choice answers to the questions. For example, the questions andpermissible answers for the standard switchboard product are shown inTABLE 1 at the end of this specification. The questions and answers areshown as they would appear on an order form, together with columns forperforming price calculations.

Referring to FIG. 13A, there is shown a flowchart of the switchboardconfiguration module. The switchboard configuration module attempts tomatch the utility metering, mains protection, and current distributionrequirements to the nineteen classes of standard switchboardconfiguration classes. The switchboard configuration module mayautomatically design from one to three or more standard switchboardsections during processing of a single order. If more than one standardswitchboard section is included in a single switchboard, then theswitchboard sections will be linked together by a through-bus connectionso that power flows from a utility metering compartment to a mainsprotection compartment and from the mains protection compartment to abranch or distribution protection compartment.

In a first step 251, the switchboard configuration module asks thequestions indicated in Appendix I about the desired switchboardspecifications. In step 252, the switchboard configuration modulereceives the answers. In step 253, the switchboard configuration moduleperforms a check for consistency among the answers. For example,specified components must be consistent with the specified systemvoltage, the specified utility company, and the local codes at aspecified delivery site.

The main and neutral ampacity and short circuit current rating, and theampacity and short circuit current rating of the main protectiondevices, must also be sufficient for the current to be supplied to thebranch protection devices and to the branch or distribution circuits.The switchboard configuration module checks constraints on the totalcurrent drawn by the branch or distribution circuits, by adding up thecurrent from each of the branch or distribution circuits, adjusting thetotal current using NEMA adjustment formulas that take intoconsideration the fact that multiple branch or distribution circuits aretypically not all in use at the same time, and comparing the sum to thetotal current constraint. This method of calculating the permissibleampacity of the section or supply bus to a number of branch circuits isknown as "diversity." In general, the permissible ampacity of thesection or supply bus is given by the following table:

    ______________________________________                                        Number of branch circuit overcurrent                                                              Percentage of the                                         protection devices supplied                                                                       sum of the ratings                                        ______________________________________                                        1                   100                                                       2-3                 80                                                        4-6                 70                                                         7-12               60                                                        Over 12             50                                                        ______________________________________                                    

These rules and specific exceptions are well known to persons skilled inthe switchboard art and are industry standards published as UL Rule 891"Dead-Front Switchboards" (Feb. 14, 1994) p. 47, and NEMA ApplicationStandards Section 6.4.1 "Calculation of Section Bus Ampacity" (PB2-1980)p. 20.

If the answers received in step 252 are inconsistent, then executionbranches from step 254 to step 255. In step 255 the switchboardconfiguration module issues a warning to the sales engineer, identifiesthe particular inconsistency discovered, and requests modification ofthe answers that are inconsistent. After receiving a response in step256, execution branches from step 257 back to step 252 to receive anynew answers. If there is no change in the inconsistent answers, thenexecution continues from step 257 to step 258 to exit to the productselector to possibly prepare a quote for a custom switchboard designthat would meet the customer's actual needs.

Once a consistent set of answers are received, the switchboardconfiguration module matches the answers to a set of standard designsfor switchboard sections. If the answers pertinent to utilityrequirements, mains protection, or branch distribution cannot be met bya standard design for a switchboard section, then a warning message isproduced by indicating the inconsistent requirements and referencing acorresponding section of a help file as shown in TABLE II at the end ofthis specification. The set of standard designs for switchboardsections, and the specifications and constraints specific to eachstandard design, are explained further below with reference to FIGS. 22to 60.

In step 259, the switchboard configuration module checks whether utilitymetering is required. If so, execution branches from step 259 to step260. In step 260, utility metering compartment(s) are allocated asrequired by utility requirements, local codes, mains and neutral currentrating, system short circuit current rating, and main feed direction andcable size. The local utility, for example, typically dictates that a"hot sequence" compartment should be allocated. If a full-height utilitycompartment for the utility supplying power to the intended buildingsite is needed to handle the specified system ampacity and utilitymetering functions, then the switchboard configuration module allocatesto the order one switchboard section having a full-height utilitycompartment. If a half height utility compartment for the utility at theintended building site can handle the specified system ampacity andutility metering functions, then the switchboard configuration moduleallocates a half height utility compartment to one half of oneswitchboard. If it is not possible to satisfy the utility meteringrequirements with a standard utility section, then execution branchesvia the dashed line path back to step 255. Otherwise, executioncontinues from step 260 to step 261 in FIG. 13B. Execution alsocontinues from step 259 to step 261 in FIG. 13B if utility metering isnot required.

In step 261 of FIG. 13B, execution branches from step 261 to step 262 toallocate a switchboard section or half a switchboard section to mainsprotection devices, as required by the mains and neutral current rating,system short circuit current rating, and desired use of main circuitbreakers or fusible switches. If only one half-height compartment wasallocated to utility metering in a switchboard section, then theswitchboard configuration module will attempt to allocate the other halfof the switchboard section to any specified mains protection. Otherwise,the switchboard configuration module will attempt to allocate a standardfull-height main circuit breaker or fuses if necessary, or if possible ahalf height main circuit breaker or fuses, in a switchboard sectionseparate from any utility section. If it is not possible to satisfy themains protection requirements with a standard switchboard section, thenexecution branches via the dashed line path and off-page connector "B"back to step 255 of FIG. 13A. Otherwise, execution continues from step262 to step 263. Execution also continues to step 263 from step 261 ifmains protection is not required.

In step 263, execution branches to step 264 to allocate a full-height orhalf-height branch or distribution protection compartment for thespecified number of distribution circuit breakers or fuses. Depending onthe number and type of the branch or distribution circuit breakers thatneed to be installed, the configuration module also checks a totalheight constraint by adding up the heights required for each of thecircuit breakers and comparing the sum to the total height constraint,in order to determine whether the circuit breakers can be containedwithin a half-height compartment or full-height compartment. If afull-height branch or distribution protection compartment is needed,then a separate switchboard section will be allocated to contain thefull-height branch or distribution protection compartment. If only ahalf-height branch or distribution protection compartment is needed, andif there is a free half of a switchboard allocated to a half-heightmains protection compartment, then the half-height branch ordistribution protection compartment will be placed in the free half ofthis switchboard; otherwise, one switchboard section will be allocatedto contain the half-height branch or distribution protectioncompartment. If it is not possible to satisfy the branch or distributioncircuit protection requirements with a standard switchboard section,then execution branches via the dashed line path and off-page connector"B" back to step 255 of FIG. 13A. Otherwise, execution continues to step265. Execution also continues from step 263 to step 265 if distributionprotection is not required.

In step 265, the switchboard configuration module allocates parts forthe interconnection of the switchboard modules and components. Next, instep 266, the switchboard configuration module gets the current price,cost, and availability of the modules, components, and parts needed formanufacture and assembly of the switchboard. Then, in step 267, theswitchboard configuration module prepares a descriptive BOM, computes atotal price and cost for the switchboard, determines whether theswitchboard can be delivered as needed by the customer, and prepares aset of drawings for the switchboard. Finally, in step 268, theswitchboard configuration module outputs the descriptive BOM; the price,cost, and delivery information; the manufacturing BOM; and the drawingsfor the switchboard.

TABLE III shows a print-out generated by the switchboard configurationmodule for a specific example. The print-out includes a generaldescription of the switchboard, a pricing detail, a price and costsummary, a quote BOM, an itemized price sheet, and the manufacturing BOMconsisting of the list of parts needed for manufacturing and assemblingthe switchboard. In this example, the switchboard configuration moduleautomatically generates the assembly drawings shown in FIGS. 14 to 19,the wiring diagram in FIGS. 20 and 21, the drawing legend shown in TABLEIV, and the table of TABLE V including a row of information for eachmodule or component in the switchboard.

The switchboard configuration module automatically generates thedrawings by selecting a set of predefined drawing templates applicableto the general classes of switchboard sections and standardconfigurations in the general classes of switchboard sections. Thenumerals and descriptive legends in FIGS. 14 to 21 are automaticallyproduced by the switchboard configuration module. For example, FIGS. 14to 16 and 18 to 19 are generally applicable to a standard switchboardsection having dimensions of about 90 inches high by 48 inches wide by24 inches deep. The front elevation in FIG. 17 is a template for aparticular standard design for a switchboard section. The numerals "6,4.5, 36, 25.5, 4.5, 6, 3" indicate the height in inches of various frontpanel sections at the front of the switchboard section in FIG. 17.

Front elevations for the various possible standard designs for aswitchboard section are shown consecutively in FIGS. 22 to 60.

FIG. 22 shows a full-height utility compartment having a top feed (2000Amp., 36" width by 24" depth; 3000 Amp., 36" width by 36" depth; 4000Amp., 42" width by 48" depth). Power is fed to the full-height utilitycompartment by service lines (not shown) that enter the full-heightutility compartment from the top and are terminated by lugs (not shown)behind an upper front panel section 301.

FIG. 23 shows a full-height utility compartment having a bottom feed(2000 Amp., 36" width by 24" depth; 3000 Amp., 36" width by 36" depth;4000 Amp., 42" width by 48" depth). Power is fed to the full-heightutility compartment by service lines (not shown) that enter thefull-height utility compartment from the bottom and are terminated bylugs (not shown) behind a lower front panel section 311.

FIG. 24 shows a full-height auxiliary section, without a power meter(through-bus and no main lugs, through-bus and main lugs, or nothrough-bus and main lugs)(width 12", 24", 30", 36", 42", 48", or 54").

FIG. 25 shows a full-height auxiliary section having a power meter 321(through-bus and no main lugs, through-bus and main lugs, or nothrough-bus and main lugs)(width 12", 24", 30", 36", 42", 48", or 54").(A box containing the abbreviation PM is to indicate the power meter 321in FIG. 24, and a similar symbol is used in elevations of otherswitchboard section designs that have power meters on their frontpanels.)

FIG. 26 shows a combo utility and main section having a top service lineentry. This switchboard section has a 36" width and a 24" depth.

FIG. 27 shows a combo utility and main section having a bottom serviceentry. This switchboard section also has a 36" width and a 24" depth.

FIG. 28 shows a full-height switchboard section having individuallymounted circuit breakers in a single main breaker type P frame (line:lugs or through-bus; load: lugs or through-bus)(2000 Amp., 3-way, 30"width, 4-way, 36" width, 24" depth).

FIG. 29 shows a full-height switchboard section having individuallymounted circuit breakers in a single main breaker type SE frame (line:lugs or through-bus; load: lugs or through-bus)(1600-3000 Amp., 42"width, 36" depth; 3001-4000 Amp. 42" width, 48" depth);

FIG. 30 shows a full-height switchboard section having an individuallymounted bolted pressure switch and a bottom feed (line: lugs orthrough-bus; load: lugs or through-bus)(800-2000 Amp., 3-way, 30" width,4-way, 36" width, 24" depth; 2500 Amp., 3-way, 36" width, 4-way, 42"width, 36" depth; 3000 Amp., 3-way, 36" width, 4-way, 42" width, 36"depth); 4000 Amp. not available for the bottom feed). The bottom feedconductors enter behind a lower front panel 331. The pressure switchescan be manually actuated by a handle 332.

FIG. 31 shows a full-height switchboard section having an individuallymounted bolted pressure switch and a top feed (line: lugs orthrough-bus; load: lugs or through-bus)(800-2000 Amp., 3-way, 30" width,4-way, 36" width, 24" depth; 2500 Amp., 3-way, 36" width, 4-way, 42"width, 36" depth; 3000 Amp., 3-way, 36" width, 4-way, 42" width, 36"depth); 4000 Amp. 3-way, 42" width, 4-way, 48", 48" depth). The top feedconductors enter behind an upper front panel 341. The pressure switchescan be manually actuated by a handle 342.

FIG. 32 shows a full-height switchboard section of stacked multiple mainbreakers (line: through-bus (600-2000 Amp. at 24"; 3000 Amp. at 36"depth; 400 Amp. at 48" depth); load: lugs (600 kcmil max.) (possiblecombinations for top and bottom main breaker are 1200 Amp top and 2500Amp. bottom; or top 2000 Amp. max. and bottom 2000 Amp. max.). Thestacked multiple main breakers can be manually actuated by respectivehandles 351 and 352.

FIG. 33 shows a full-height switchboard section of stacked multiple mainfusible pressure switches (line: through-bus (600-2000 Amp. at 24" depthfor type CB, 36" depth for type BP; 3000 Amp. at 36" depth; 400 Amp. at48" depth); load: lugs (600 kcmil max.); possible combinations for topand bottom main breaker are 1600 Amp. max top and 2000 Amp. max.bottom).

FIG. 34 shows a full-height switchboard distribution section withI-LINE® circuit breakers, or six circuit mains, bottom feed, with orwithout through-bus, 1200 Amp. max left circuit breakers, 250 Amp. maxright circuit breakers, 48" width, 24" depth. A main lug entry for 2000Amp. max is located behind a lower front panel section 361.

FIG. 35 shows a full-height switchboard section with I-LINE® circuitbreaker distribution, or six circuit mains, top feed, with or withoutthrough-bus, 1200 Amp. max. left circuit breakers, 250 Amp. max. rightcircuit breakers, 48" width, 24" depth. A main lug entry for 2000 Amp.max is located behind an upper front panel section 371.

FIG. 36 shows a full-height switchboard section for main lug and fusibledistribution or six circuit mains (type QMB or QMJ), bottom feed, withor without through-bus; 400 Amp. max. fusible switch, 36" width; 1200Amp. max. fusible switch, 42" width. A main lug entry for 2000 Amp. maxis located behind a lower front panel section 381.

FIG. 37 shows a full-height switchboard section for main lug and fusibledistribution or six circuit mains (type QMB or QMJ), top feed, with orwithout through-bus, 2000 Amp. max (400 Amp. max fusible switch, 36"width; 1200 Amp. max fusible switch, 42" width). A main lug entry for2000 Amp. max is located behind an upper front panel section 391.

FIG. 38 shows a full-height switchboard section for a main lug combodouble row I-LINE® circuit breaker distribution or six circuit mains,bottom feed, with or without through-bus. The section depth is 24inches. For a 48 inch width, the left circuit breakers are 800 Amp. max,and the right circuit breakers are 250 Amp. max. For a 42 inch width,the left circuit breakers are 600 Amp. max and the right circuitbreakers are 250 Amp. max. For a 36 inch width, the left circuitbreakers can have 250 Amp. max and the right circuit breakers are 100Amp. max. Power is received in section by a bottom entry 2000 Amp. maxmain lug compartment 401.

FIG. 39 shows a full-height switchboard section for a main lug combodouble row I-LINE® circuit breaker distribution or six circuit mains,top feed, with or without through-bus. The section depth is 24 inches.For a 48 inch section width, the left circuit breakers are 800 Amp. max,and the right circuit breakers are 250 Amp. max. For a 42 inch width,the left circuit breakers are 600 Amp. max and the right circuitbreakers are 250 Amp. max. For a 36 inch width, the left circuitbreakers can have 250 Amp. max and the right circuit breakers are 100Amp. max. Power is received in a top entry 2000 Amp. max main lugcompartment 411.

FIG. 40 shows a full-height switchboard section for a main lug I-LINE®single row combo distribution or six circuit mains with or withoutthrough-bus and a bottom feed. Main lugs for the bottom feed, 2000 Amp.max, are located in a lower compartment 421. The circuit breakers are800 Amp. max. The section has a width of 36 inches and a depth of 24inches.

FIG. 41 shows a full-height switchboard section for a main lug I-LINE®single row combo distribution or six circuit mains with or withoutthrough-bus and a top feed. Main lugs for the bottom feed, 2000 Amp.max., are located in an upper compartment 431. The circuit breakers are800 Amp. max. The section has a width of 36 inches and a depth of 24inches.

FIG. 42 shows a full-height switchboard section including main lugs andtype QMB or QMJ fusible distribution or six circuit mains and a bottomfeed with or without a through-bus. The section depth is 42 inches. A400 Amp. max fusible switch is used for a switchboard section having awidth of 36 inches, and an 800 Amp. max fusible switch is used for aswitchboard section having a width of 42 inches. Main lugs for thebottom feed, 2000 Amp. max., are located in a lower compartment 441.

FIG. 43 shows a full-height switchboard section including main lugs andtype QMB or QMJ fusible distribution or six circuit mains and a top feedwith or without a through-bus. The section depth is 42 inches. A 400Amp. max fusible switch is used for a switchboard section having a widthof 36 inches, and an 800 Amp. max fusible switch is used for aswitchboard section having a width of 42 inches. Main lugs for the topfeed, 2000 Amp. max., are located in an upper compartment 451.

FIG. 44 shows a full-height combo switchboard section having a lowerhalf-height main circuit breaker compartment 461 and an upperhalf-height distribution circuit breaker compartment 462. Thedistribution circuit breaker compartment 462 has two rows of I-LINE®distribution circuit breakers. The section depth is 48 inches. Thedistribution breakers are 250 Amp. max left breakers and 100 Amp. maxright breakers for a 36 inch section width, 600 Amp. left circuitbreakers and 250 Amp. max right circuit breakers for a 42 inch width,and an 800 Amp. max left circuit breakers and 250 Amp. max right circuitbreakers for a 48 inch width. Service lines are connected by main lugsand the load may or may not be connected by a through-bus.

FIG. 45 shows a full-height combo switchboard section having an upperhalf-height main circuit breaker compartment 471 and a lower half-heightdistribution circuit breaker compartment 472. The distribution circuitbreaker compartment 472 has two rows of I-LINE® distribution circuitbreakers. The section depth is 48 inches. The distribution breakers are250 Amp. max left breakers and 100 Amp. max right breakers for a 36 inchsection width, 600 Amp. left circuit breakers and 250 Amp. max rightcircuit breakers for a 42 inch width, and an 800 Amp. max left circuitbreakers and 250 Amp. max right circuit breakers for a 48 inch width.Service lines are connected main lugs and the load may or may not beconnected by a through-bus.

FIG. 46 shows a full-height combo switchboard section with a bottom feedand including a half-height main breaker compartment 381 and ahalf-height distribution breaker compartment 382 for I-LINE® single rowdistribution breakers. The bottom feed including lugs or a bus way orthrough-bus received behind a lower front-panel section 383. The mainbreaker has a rating of 2000 Amp. 100% max. Distribution breakers are800 Amp. max. The switchboard section has a 36 inch width and a 24 inchdepth.

FIG. 47 shows a full-height combo switchboard section with a top feedand including a half-height main breaker compartment 391 and ahalf-height distribution breaker compartment 392 for I-LINE® single rowdistribution breakers. The top feed including lugs or a bus way orthrough-bus received behind an upper front-panel section 393. The mainbreaker has a rating of 2000 Amp. 100% max. Distribution breakers are800 Amp. max. The switchboard section has a 36 inch width and a 24 inchdepth.

FIG. 48 shows a full-height switchboard section containing a single-rowof distribution circuit breakers internally connected to a 2000 Amp.vertical bus. Service lines are connected by lugs with no through bus, abus way with no through bus, a through bus or lugs on the through bus.The load is connected by breaker lugs. The breakers are 1200 Amp. max.The section has a 36 inch width and a 24 inch depth. The 1200 Amp. maxbreakers can be thermo-magnetic or electronic.

FIG. 49 shows a full-height switchboard section including a double-rowof I-LINE® breakers. Power to the circuit breakers is conveyed by aninternal 2000 Amp. vertical bus. A 34 inch width switchboard section canhave 250 Amp. max left breakers and 100 Amp. max right breakers. A 42inch width section can have 600 Amp. max left breakers and 250 Amp. maxright breakers. A 48 inch width section can have 1200 Amp. max leftbreakers and 250 Amp. max right breakers.

FIG. 50 shows a full-height switchboard section for up to two rows ofcircuit breakers fed by a 3000 or 4000 Amp. internal vertical bus.Breakers in a left row 401 are 1200 Amp. max breakers, and breakers inan upper portion 402 and a lower portion 403 of a right row are 250 Amp.max breakers. The width of the switchboard section is 54 inches. For a3000 Amp. internal bus, the section has a 36 inch depth. For a 4000 Amp.internal vertical bus, the switchboard section has a depth of 48 inches.

FIG. 51 shows a full-height combo section including a lower fusible mainswitch compartment 411 and an upper distribution circuit breakercompartment 412. The fusible main switch 413 is 2000 Amp. max. Servicelines are received behind a bottom front panel section 414 and the loadsare connected behind an upper front panel section 415. The serviceconnections are by lugs or bus way or through-bus and the load may ormay not be a through-bus. The depth of the section is 24 inches. For a36 inch section width, the left distribution circuit breakers are 250Amp. max and the right distribution circuit breakers are 100 Amp. max.For a 42 inch section width, the left distribution circuit breakers are600 Amp. max and the right distribution circuit breakers are 250 Amp.max. For a 48 inch section width, the left distribution circuit breakersare 800 Amp.max and the right distribution circuit breakers are 250 Amp.max.

FIG. 52 shows a full-height combo section including an upper fusiblemain switch compartment 416 and a lower distribution circuit breakercompartment 417. The fusible main switch 418 is 2000 Amp. max. Servicelines are received behind an upper front panel section 419 and the loadsare connected behind a lower front panel section 420. The service linesare connected by lugs or bus way or through-bus and the load may or maynot be a through-bus. The depth of the section is 24 inches. For a 36inch section width, the left distribution circuit breakers are 250 Amp.max and the right distribution circuit breakers are 100 Amp. max. For a42 inch section width, the left distribution circuit breakers are 600Amp. max and the right distribution circuit breakers are 250 Amp. max.For a 48 inch section width, the left distribution circuit breakers are800 Amp. max and the right distribution circuit breakers are 250 Amp.max.

FIG. 53 shows a full-height combo switchboard section including a lowerfusible main compartment 421 and an upper single-row distributioncircuit breaker compartment 422. A main fusible switch 423 has a 2000Amp. max rating. The distribution breakers are rated at 800 Amp. max.The switchboard section has a 36 inch width and a 24 inch depth. Servicelines are received by lugs on main or through-bus behind a lower frontpanel section 424 and the lugs may or may not be provided to athrough-bus. The loads extend from behind an upper front panel section425.

FIG. 54 shows a full-height combo switchboard section including an upperfusible main compartment 431 and a lower single-row distribution circuitbreaker compartment 432. A main fusible switch 433 has a 2000 Amp. maxrating. The distribution breakers are rated at 800 Amp. max. Theswitchboard section has a 36 inch width and a 24 inch depth. Servicelines are received by lugs on main or through-bus behind an upper frontpanel section 434 and the lugs may or may not be provided to athrough-bus. The loads extend from behind a lower front panel section435.

FIG. 55 shows a full-height combo switchboard section including a lowerfusible main compartment 441 and an upper fusible distributioncompartment 442. A fusible main switch 443 is rated at 2000 Amp. max.The section depth is 24 inches. The distribution fuses 442 are 400 Amp.max type QMB or QMJ in a 36 inch section width, or an 800 Amp. max typeQMB or QMJ in a 42 inch section width. Service lines are connected bylugs or a through-bus and the load may or may not be supplied through athrough-bus.

FIG. 56 shows a full-height combo switchboard section including an upperfusible main compartment 451 and a lower fusible distributioncompartment 452. A fusible main switch 453 is rated at 2000 Amp. max.The section depth is 24 inches. The distribution fuses in the lowercompartment 452 are 400 Amp. max type QMB or QMJ in a 36 inch sectionwidth, or an 800 Amp. max type QMB or QMJ in a 42 inch section width.Service lines are connected by lugs or a through-bus and the load may ormay not be supplied through a through-bus.

FIG. 57 shows a full-height switchboard section for fusible distributionincluding an upper line feed to an 800 Amp. max type QMB fusible mainswitch 461 and a lower compartment 462 including type QMB fusibleswitches for distribution to lower load lines. The section depth is 24inches. The distribution switches 462 are 400 Amp. max type QMB for a 36inch width section, or an 800 Amp. max type QMB for a 42 inch widthsection. Service lines are connected by lugs or a through-bus and theload is or is not supplied by a through-bus.

FIG. 58 shows a full-height switchboard section for fusible distributionincluding a lower line feed to an 800 Amp. max type QMB fusible mainswitch 471 and an upper compartment 472 including type QMB fusibleswitches for distribution to upper load lines. The section depth is 24inches. The distribution switches in the upper compartment 472 are 400Amp. max type QMB for a 36 inch width section, or an 800 Amp. max typeQMB for a 42 inch width section. Service lines are connected by lugs ora through-bus and the load is or is not supplied by a through-bus.

FIG. 59 is a full-height section for fusible distribution. The fusibledistribution switches 475 are fed by an internal 2000 Amp. vertical bus.The switches 475 are 400 Amp. max type QMB or QMJ for a 36 inch sectionwidth, and 1200 Amp. max QMB or QMJ for a 42 inch section. There can beone 1200 Amp. max per section or three 800 max per section.

FIG. 60 shows a full-height switchboard section for fusible distributionfrom an internal 3000 Amp. vertical bus. There can be a maximum of two1200 Amp. max QMB or QMJ fusible switches 481 and 482. Service lines canbe connected by lugs or bus way, or a through-bus or lugs on athrough-bus, or a bus way to a through-bus.

The new switchboard sales and production methodology has cut the cycletime at Square D Co. for a typical switchboard from about eight weeks toone day. The customer can usually get a switchboard in one day, ifneeded. There has been a reduction of about 95% in errors in theordering process, and a corresponding increase in customer satisfaction.The profit margin for switchboards has been substantially increased.

The new switchboard sales and production methodology has a few aspectsthat run counter to conventional wisdom for sales and productionmanagement. The conventional wisdom was to individually optimizeseparate processes. However, for switchboards, processes in the salesand production methodology were misaligned in the pipeline of valuecreation. Better alignment of those processes, including sales, pricing,engineering design, sourcing of materials, and manufacturing, has beenfound to be more important than the individual optimization of theprocesses. Therefore, the traditional functional optimization measureshave been replaced with the more important financial and non-financialmeasures to drive process alignment. In particular, focus has shiftedfrom the traditional measures of component cost and plant utilization toprofit margin, error rate, cycle and lead time, and customersatisfaction. For example, a switchboard automatically configured fromone of the nineteen standard configuration classes is more likely toinclude a higher degree of functional complexity than a custom designedswitchboard, and the customer may not need this higher degree offunctional complexity. Yet in the overall process, it is better toautomatically configure a switchboard from one of the nineteen standardconfiguration classes when it is possible to do so.

                                      TABLE I                                     __________________________________________________________________________    QUESTIONS AND ANSWERS FOR STANDARD SWITCHBOARD                                __________________________________________________________________________    QED-S         STANDARD PRODUCT OFFERING                                       The QED-S Power-Style Switchboard                                             Program is designed to meet your                                              customers shipping requirements by                                            reducing cycle times                                                          The QED-S program consists of:                                                □ 4000 amperes maximum                                             □ UL Type 1 or Type 3R                                             □ Heat Rise or Current Density Bus                                 □ Front and Rear Alignment                                         □ Incoming Lugs: Mechanical or Compression                         □ Suitable For Use on Service Entrance                             Project Name:                                                                 Switchboard Designation:                                                      Distributor                                                                   Distributor PO#:                                                                            Acct. #:                                                        Contractor:                                                                   Arch/Engr:                                                                    Priced By:                                                                    Customer                                                                      Street:                                                                       City:                                                                         State/ZIP:                                                                    Attention:                                                                    Mark:                                                                         SPD:     Q2C:                                                                 Main &                                                                        Neutral                                                                       Al or CU                                                                            CU                                                                      □ 600                                                                    □ 2500                                                       □ 800                                                                    □ 3000                                                       □ 1000                                                                   □ 4000                                                       □ 1200                                                             □ 1500                                                             □ 1600                                                             □ 2000                                                             System                                                                        □ 208Y/12O 3P4W                                                    □ 240/120 3P4W                                                     □ 48OY/277 3P4W                                                    □ 480 3P3W                                                          □ Grounded Wye                                                     □ Grounded Delta                                                  Bus Bar Material                                                              Heat Rise (Std.)                                                              □ Standard AI/Cu                                                   □ Copper Only                                                      Current Density                                                               □ 1000A/in.sup.2 Cu                                                □ 700A/in.sup.2 AI                                                 □ 750A/in.sup.2 AI                                                 Short Circuit                                                                 Current Rating                                                                □ 18k                                                              □ 25k                                                              □ 30k                                                              □ 42k                                                              □ 50k                                                              □ 65k                                                              □ 100k                                                             □ 125k                                                             □ 150k                                                             □ 200k                                                             Incoming Feed                                                                 Direction                                                                     □ Bottom Left                                                      □ Bottom Right                                                     □ Top Left                                                         □ Top Right                                                        Accessibility                                                                 □ Front Only                                                       Front and:                                                                    □ Left                                                             □ Right                                                            □ Rear                                                             Enclosure Type                                                                □ NEMA Type 1                                                      □ NEMA Type 3R                                                     Non-Walk-In                                                                   Through Bus                                                                   □ Yes                                                              □ No:                                                               Single Section                                                                Lugs Load-Side                                                               □                                                                    Suitable for Use As Service Equipment                                       □                                                                    Series Rated                                                                Incoming Cable Size: No. Per Phase                                                            Wire Size                                                     □                                                                    On-site Date:                                                               Utility Company                                                               Name:                                                                         Local Codes:                                                                  □ Chicago                                                          □ New York                                                         __________________________________________________________________________    INDIVIDUALLY MOUNTED MAINS, BRANCHES AND QMB                                  Incoming Sections                                                             12" High  12" High                                                                           Main Lugs         Utility Compartment                                                                        Auxilliary                      System                                                                             Pull Pull Box                                                                           Al   Al  Cu   Cu           Double                                                                            (Empty)                                                                            Section                                                                           Unit                                                                              Total              Amps Box  w/barrier                                                                          3W   4W  3W   4W  3W  4W   Door                                                                              24"W >24"W                                                                             List                                                                              List               __________________________________________________________________________     800 $740 $1080                                                                              $1940                                                                              $2265                                                                             $2615                                                                              $3050                                                                             $1245                                                                             $1775                                                                              $275                                                                              $1930                                                                              $2305                      1200 ↓                                                                           ↓                                                                           2645 2975                                                                              3575 4020                                                                              1700                                                                              2475 ↓                                                                          ↓                                                                           ↓                   1600 ↓                                                                           ↓                                                                           3285 3735                                                                              4445 5045                                                                              2495                                                                              3645 ↓                                                                          ↓                                                                           ↓                   2000 ↓                                                                           ↓                                                                           3945 4475                                                                              5330 6035                                                                              2495                                                                              4365 ↓                                                                          ↓                                                                           ↓                   2500 ↓                                                                           ↓                                                                           5255 5955                                                                              6180 7005                                                                              2930                                                                              4990 ↓                                                                          ↓                                                                           ↓                   3000 ↓                                                                           ↓                                                                           6360 7070                                                                              7485 8310                                                                              3300                                                                              5330 ↓                                                                          ↓                                                                           ↓                   4000 ↓                                                                           ↓                                                                           --   --  9475 10670                                                                             3745                                                                              7194 ↓                                                                          ↓                                                                           ↓                                                             Incoming Sections                   __________________________________________________________________________                                              Sub-Total:                          Maximum  Short Circuit                                                                         List                                                                              Accessories/Options:                                     C/B  Percent                                                                           Current Rating                                                                        Price                                                                             Alarm                                                                              Aux Shunt  Trips:            Unit                                                                              Total              Frames                                                                             Rated                                                                             480V                                                                              240V                                                                              3 Pole                                                                            Switch                                                                             1A1B                                                                              Trip (120Vac)                                                                        GFP/PTT                                                                             Short                                                                             TI/LCA                                                                            Qty List.                                                                             List               __________________________________________________________________________    Thermal Magnet Fixed Mounted C/B:                                             MA1000                                                                             80% 30k 42k $8820                                                                             Not  $220                                                                              $565   --    --  --                             MH1000                                                                             ↓                                                                          65k 65k 11020                                                                             Available                                                                          ↓                                                                          ↓                                                                             --    --  --                             PA1600                                                                             ↓                                                                          50k ↓                                                                          14626                                                                             ↓                                                                           ↓                                                                          ↓                                                                             --    --  --                             PA2000                                                                             ↓                                                                              ↓                                                                          16280                                                                             ↓                                                                           ↓                                                                          ↓                                                                             --    --  --                             PH1600                                                                             ↓                                                                          100k                                                                              125k                                                                              15440                                                                             ↓                                                                           ↓                                                                          ↓                                                                             --    --  --                             PH2000                                                                             ↓                                                                          ↓                                                                          ↓                                                                          20115                                                                             ↓                                                                           ↓                                                                          ↓                                                                             --    --  --                             PC2000                                                                             ↓                                                                          ↓                                                                          ↓                                                                          20765                                                                             ↓                                                                           ↓                                                                          ↓                                                                             --    --  --                             PC2500                                                                             ↓                                                                          ↓                                                                          ↓                                                                          24560                                                                             ↓                                                                           ↓                                                                          ↓                                                                             --    --  --                             Solid State Fixed Mounted C/B:                                                MX0800                                                                             80  65k 65k  9380                                                                             Not  $220                                                                              $565   $1660 Std.                                                                              $920                           ME0800                                                                             100         11050                                                                             Available                                                                          ↓                                                                          ↓                                                                             2755  2335                                                                              Std.                           PX1200                                                                             80  100k                                                                              125k                                                                              14090                                                                             ↓                                                                           ↓                                                                          ↓                                                                             1660  STD.                                                                              920                            PX1600                                                                             ↓                                                                          ↓                                                                          ↓                                                                          15445                                                                             ↓                                                                           ↓                                                                          ↓                                                                             1660  ↓                                                                          ↓                       PX2000                                                                             ↓                                                                          ↓                                                                          ↓                                                                          19390                                                                             ↓                                                                           ↓                                                                          ↓                                                                             1660  ↓                                                                          ↓                       PX2500                                                                             ↓                                                                          ↓                                                                          ↓                                                                          25215                                                                             ↓                                                                           ↓                                                                          ↓                                                                             1660  ↓                                                                          ↓                       PE1200                                                                             100 ↓                                                                          ↓                                                                          19210                                                                             ↓                                                                           ↓                                                                          ↓                                                                             2755  2335                                                                              STD.                           PE1600                                                                             ↓                                                                          ↓                                                                          ↓                                                                          22395                                                                             ↓                                                                           ↓                                                                          ↓                                                                             2755  ↓                                                                          ↓                       PE2000                                                                             ↓                                                                          ↓                                                                          ↓                                                                          23460                                                                             ↓                                                                           ↓                                                                          ↓                                                                             2755  ↓                                                                          ↓                       PE2500                                                                             80  ↓                                                                          ↓                                                                          38325                                                                             ↓                                                                           ↓                                                                          ↓                                                                             2755  ↓                                                                          ↓                       Stored Energy Fixed Mounted C/B:                                              SEF1600                                                                            100 100k                                                                              150k                                                                              28140                                                                             $1500    $850   $2755 $2335                                                                             STD                            SEF2000                                                                            ↓                                                                          ↓                                                                              35185                                                                             ↓ ↓                                                                             ↓                                                                            ↓                                                                          ↓                       SEF2500                                                                            ↓                                                                          ↓                                                                              42955                                                                             ↓ ↓                                                                             ↓                                                                            ↓                                                                          ↓                       SEF3000                                                                            ↓                                                                          ↓                                                                              48055                                                                             ↓ ↓                                                                             ↓                                                                            ↓                                                                          ↓                       SEF4000                                                                            ↓                                                                          ↓                                                                              70782                                                                             ↓ ↓                                                                             ↓                                                                            ↓                                                                          ↓                            ↓                                                                          ↓    ↓ ↓                                                                             ↓                                                                            ↓                                                                          ↓                       __________________________________________________________________________    BOLT-LOC BP Fixed Mounted F/S:                                                                                                       Unit                                                                              Total              Frame                                                                              %   480V                                                                              240V                                                                              3 Pole                                                                            Bottom                                                                             BMFD                                                                              PFR/CAP                                                                              GFP   Fuses                                                                             1A1B                                                                              Qty List                                                                              List               __________________________________________________________________________    BP0800                                                                             100 200k                                                                              200k                                                                              $11400                                                                            $1440                                                                              $780                                                                              $5325  $9145 $2715                                                                             $515                           BP1200                                                                             ↓                                                                          ↓                                                                          ↓                                                                          13030                                                                             ↓                                                                           ↓                                                                          ↓                                                                             ↓                                                                            ↓                                                                          ↓                       BP1600                                                                             ↓                                                                          ↓                                                                          ↓                                                                          14105                                                                             ↓                                                                           ↓                                                                          ↓                                                                             ↓                                                                            ↓                                                                          ↓                       BP2000                                                                             ↓                                                                          ↓                                                                          ↓                                                                          18020                                                                             ↓                                                                           ↓                                                                          ↓                                                                             10375 ↓                                                                          ↓                       BP2500                                                                             ↓                                                                          ↓                                                                          ↓                                                                          20940                                                                             ↓                                                                           ↓                                                                          ↓                                                                             11505 ↓                                                                          ↓                       BP3000                                                                             ↓                                                                          ↓                                                                          ↓                                                                          34670                                                                             ↓                                                                           ↓                                                                          ↓                                                                             ↓                                                                            ↓                                                                          ↓                       BP4000                                                                             ↓                                                                          ↓                                                                          ↓                                                                          45610                                                                             NA   ↓                                                                          ↓                                                                             12910 ↓                                                                          ↓                                                     Main and Distribution Sub-Total:                __________________________________________________________________________    QMB Fixed Mounted Single Main F/S:                                            SCCR     QMB         Fuses Installed                   Height                                                                            Total              Frame                                                                              480V                                                                              Clips                                                                             3-Pole                                                                            2-Pole                                                                            3-Pole                                                                             2-Pole                       25.5"                                                                             List               __________________________________________________________________________    400  200k                                                                              J,R $4655                                                                             $3955                                                                             --   --                               $                  600  100k                                                                              J,R 5245                                                                              4455                                                                              --   --                                                  800  200k                                                                              L   9945                                                                              8455                                                                              $2715                                                                              $1810                                                                             QMB Main Switch Sub-Total                       __________________________________________________________________________    GROUP MOUNTED I-LNE CIRCUIT BREAKERS                                          I-LINE                                                                        C/B                                                                           Frame &                  2 or 3                                                                           Options:                  Total                                                                            Unit                                                                             Total             Max  SCCR  Height                                                                              List Prices:                                                                          Pole                                                                             Aux.S.W.                                                                           Shunt Trips          Mfg.                                                                             List                                                                             List              Amp. 480V                                                                             240V                                                                             3P 2P 3P  2P  Space                                                                            1A&1B                                                                              Trip (120V)                                                                         Short                                                                            GFP/PTT                                                                            TI/LCA                                                                            QTY.                                                                             HT.                                                                              Price                                                                            Price             __________________________________________________________________________    FA060                                                                              18k                                                                              25k                                                                              4.5"                                                                             4.5"                                                                              510                                                                               365                                                                              $50                                                                              $220 $305  -- $2535                                                                              --                             FA100      ↓                                                                         ↓                                                                          530                                                                               445                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             FH060                                                                              25k                                                                              65k                                                                              ↓                                                                         ↓                                                                          740                                                                               625                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             FH100      ↓                                                                         ↓                                                                          775                                                                               715                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             FC060                                                                              65k                                                                              100k                                                                             ↓                                                                         ↓                                                                          955                                                                               765                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             FC100      ↓                                                                         ↓                                                                         1175                                                                               940                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             FI100                                                                              200k                                                                             200k                                                                             ↓                                                                         ↓                                                                         2175                                                                              1775                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             KA225                                                                              25k                                                                              42k                                                                              ↓                                                                         ↓                                                                         1440                                                                              1130                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             KA250      ↓                                                                         ↓                                                                         2390                                                                              1970                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             KH225                                                                              35k                                                                              65k                                                                              ↓                                                                         ↓                                                                         3135                                                                              2630                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             KH250      ↓                                                                         ↓                                                                         3985                                                                              3215                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             KC225                                                                              65k                                                                              100k                                                                             ↓                                                                         ↓                                                                         3470                                                                              2775                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             KC250      ↓                                                                         ↓                                                                         4250                                                                              3400                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             KI225                                                                              200k                                                                             200k                                                                             ↓                                                                         ↓                                                                         4065                                                                              3175                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             KI250      ↓                                                                         ↓                                                                         4730                                                                              3705                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- ↓                                                                           --                             LA400                                                                              30k                                                                              42k                                                                              6" 6" 2505                                                                              2035                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- --   --                             LH400                                                                              35k                                                                              65k      4195                                                                              3430                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- --   --                             LC400                                                                              65k                                                                              100k                                                                             7.5"                                                                             7.5"                                                                             5080                                                                              4320                                                                              220                                                                              ↓                                                                           ↓                                                                            -- --   --                             LC600      ↓                                                                         ↓                                                                         5215                                                                              4460                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- --   --                             LI400                                                                              200k                                                                             200k                                                                             ↓                                                                         ↓                                                                         5815                                                                              4940                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- --   --                             LI600      ↓                                                                         ↓                                                                         7920                                                                              7125                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- --   --                             MA600                                                                              30k                                                                              42k                                                                              9" 9" 4155                                                                              3225                                                                              290                                                                              ↓                                                                           565   -- --   --                             MA800      ↓                                                                         ↓                                                                         5205                                                                              4175                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- --   --                             MH600                                                                              65k                                                                              65k                                                                              ↓                                                                         ↓                                                                         5580                                                                              4350                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- --   --                             MH800      ↓                                                                         ↓                                                                         6785                                                                              5165                                                                              ↓                                                                         ↓                                                                           ↓                                                                            -- --   --                             NA1200                                                                             50k                                                                              100k                                                                             15"                                                                              15"                                                                              10180                                                                             9150                                                                              345                                                                              ↓                                                                           ↓                                                                            -- --   --                             NC1200                                                                             100k                                                                             125k     12505                                                                             11240  ↓                                                                           ↓                                                                            -- --   --                             LX250                                                                              65k                                                                              100k                                                                             7.5"                                                                             7.5"                                                                             5050                                                                              3790                                                                              220                                                                              ↓                                                                           305   STD.                                                                             $1660                                                                              920                            LX400                                                                              ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         5425                                                                              4625                                                                              ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                         ↓                                                                           ↓                       LX600                                                                              ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         7785                                                                              6030                                                                              ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                         ↓                                                                           ↓                       LX1250                                                                             200k                                                                             200k                                                                             ↓                                                                         ↓                                                                         8280                                                                              6835                                                                              ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                         ↓                                                                           ↓                       LX1400                                                                             ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         10465                                                                             9105                                                                              ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                         ↓                                                                           ↓                       LX1600                                                                             ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         15570                                                                             13810                                                                             ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                         ↓                                                                           ↓                       LE250                                                                              65k                                                                              100k                                                                             ↓                                                                         ↓                                                                         7575                                                                              5375                                                                              ↓                                                                         ↓                                                                           ↓                                                                            2335                                                                             2755 STD.                           LE400                                                                              ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         8105                                                                              6750                                                                              ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                              ↓                       LE600                                                                              ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         9170                                                                              7415                                                                              ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                              ↓                       MX250                                                                              65k                                                                              65k                                                                              9" 9" 6270                                                                              5005                                                                              290     565   STD.                                                                             1660 920                            MX400                                                                              ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         7675                                                                              5425                                                                              ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                         ↓                                                                           ↓                       MX800                                                                              ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         8780                                                                              7025                                                                              ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                         ↓                                                                           ↓                       ME250                                                                              ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         7835                                                                              6575                                                                              ↓                                                                         ↓                                                                           ↓                                                                            2335                                                                             2755 Std.                           ME400                                                                              ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         8340                                                                              6985                                                                              ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                         ↓                                                                           ↓                       ME800                                                                              ↓                                                                         ↓                                                                         ↓                                                                         ↓                                                                         10345                                                                             8590                                                                              ↓                                                                         ↓                                                                           ↓                                                                            ↓                                                                         ↓                                                                           ↓                       NX1200                                                                             100k                                                                             125k                                                                             15"                                                                              15"                                                                              12660                                                                             10135                                                                             345                                                                              ↓                                                                           ↓                                                                            Std.                                                                             1660 920                            NE1200                                                                             100k                                                                             125k                                                                             15"                                                                              15"                                                                              17790                                                                             15255                                                                             345                                                                              ↓                                                                           ↓                                                                            2335                                                                             2755 Std.                                                                     I-LINE Sub-Total                    __________________________________________________________________________    Qty.                                                                              Frame                                                                             Amp.                                                                             P  ACC.          Qty. Frame Amp.                                                                             P    ACC.                           __________________________________________________________________________    INCOMING SECTIONS, CUSTOMER METERING, SECTIONS CHARGES                        QMB/J Group Mounted Branch F/S:                                                                SCCR QMB  QMJ Switches Space                                                                              Auxiliary Total                                                                             Total              Switch                                                                              QMB Ht.                                                                            QMJ Ht.                                                                             480V Clips                                                                              Clips                                                                             480V 240V                                                                              3 Pole                                                                             1A1B Qty. Height                                                                            List               __________________________________________________________________________    30--30                                                                              4.5" Twin  200k J,R  J   $1645                                                                              1145                                                                              $180 $250          $                  30-blank                                                                            4.5" Twin  ↓                                                                           ↓                                                                           ↓                                                                          1235  860                                                                              180  ↓                         60--60                                                                              6" Twin    ↓                                                                           ↓                                                                           ↓                                                                          1645 1145                                                                              300  ↓                         60-blank                                                                            6" Twin    ↓                                                                           ↓                                                                           ↓                                                                          1235  860                                                                              300  ↓                         100--100                                                                            7.5" Twin                                                                          6" Twin                                                                             ↓                                                                           ↓                                                                           ↓                                                                          2400 1455                                                                              300  ↓                         100-blank                                                                           7.5" Twin                                                                          6" Twin                                                                             ↓                                                                           ↓                                                                           ↓                                                                          1690 1095                                                                              300  ↓                         200--200                                                                            N/A  7.5" Twin                                                                           ↓                                                                           ↓                                                                           ↓                                                                          4111 4111                                                                              300  ↓                         200-blank                                                                           N/A  7.5" Twin                                                                           ↓                                                                           ↓                                                                           ↓                                                                          2055 2055                                                                              300  ↓                         200   9" Single                                                                          N/A   ↓                                                                           ↓                                                                           ↓                                                                          2055 1665                                                                              360  ↓                         400   15" Single                                                                         9" Single                                                                           ↓                                                                           ↓                                                                           ↓                                                                          3965 2480                                                                              600  --                               600   15" Single 100k ↓                                                                           ↓                                                                          4555 3490                                                                              600  --                               800   15" Single 200k L    L   7300 5445                                                                              600  --                               1200  24" Single 100k          9080 9080                                                                              960  --                                                                                 QMB Sub-Total               __________________________________________________________________________    Main Customer Metering (Device(s) or Switchboard):                                       480Y/277                                                                            Current Transformers (each) 3W = 2CT's 4W                                                                      Potential Transformers                 VPM   800  1600 2500                                                                              4000 QTY X Price                                                                            3W   4W       Total              __________________________________________________________________________    PM600 $7260                                                                              --    $750 $1450                                                                              $1620                                                                             $1710         --   --                          PM620  8712                                                                              --    ↓                                                                           ↓                                                                           ↓                                                                          ↓      --   --                          CM2150                                                                               9625                                                                              $1200 ↓                                                                           ↓                                                                           ↓                                                                          ↓      $2790                                                                              $4185                       CM2250                                                                              11385                                                                              ↓                                                                            ↓                                                                           ↓                                                                           ↓                                                                          ↓      ↓                                                                           ↓                    CM2350                                                                              12870                                                                              ↓                                                                            ↓                                                                           ↓                                                                           ↓                                                                          ↓      ↓                                                                           ↓                    CM2450                                                                              13979                                                                              ↓                                                                            ↓                                                                           ↓                                                                           ↓                                                                          ↓      ↓                                                                           ↓                                                                 Customer Metering                __________________________________________________________________________                                                 Sub-Total                        Group Mounted Devices      Section                                            I-LINE                     Charge    700 &          NEMA  Total               2000A 63" high full height System    750A/     1000A/                                                                             Type                                                                                Qty.                2000A 54" high Main Lugs   Amps AL.  In.sup.2 AL                                                                        CU.  IN.sup.2                                                                           Adder (P                                                                            X                   __________________________________________________________________________                                                              Charge              2000A 36" high with P-frame, one per line-up                                                              800 $3,720                                                                             $4,930                                                                             $5,020                                                                             $5,020                                                                             $2,375                    2000A 27" high with BOLT-LOC, one per line-up                                                            1200 4,320                                                                              ↓                                                                           5830  7500                          3000A 72" high full height 1600 4,930                                                                              --   6665 ↓                       QMB                        2000 5,450                                                                              --   7500 ↓                       30" Interior available, One per Line-up, 800A maximum switch                                             2500 --   --   8750 12910                          72" Interior available 2000A or 3000A, 1200A maximum switch                                              3000 --   --   10635                                                                              ↓                       Additional Features        4000 --   --   12910                                                                              ↓                       Nameplates $75 each Qty.    Sub-Total                                                             $                     Section Charge Sub-Total            Incoming Compression lugs (No Charge)                                                             □ Yes                                          Bottom Closure Plate(s) $320 each Qty.                                                            Sub-Total        PRICE SUMMARY                            Special Barriers Steel $995, Insulating $1990, Qty                                                                 ULSE $665 (page 1)                                                            Incoming sections Sub-total (page                                             2)                                                                            Main and Distribution Sub-Total                                               (page 2)                                                                      QMB Main Switch Sub-Total (page 2)                                            I-LINE Sub-Total (page 3)                                                     QMB Sub-Total (page 4)                                                        Customer Metering Sub-Total (page                                             4)                                                                            Section Charge Sub-Total (page 4)                                             Nameplates Sub-Total (page 4)                                                 Bottom Closure Plates Sub-Total                                               (page 4)                                                                      Special Barriers                                                              3000A I-LINE Charge  $6555 x Qty                                                             Grand Total:                                                                  xPE1-                     __________________________________________________________________________

                                      TABLE II                                    __________________________________________________________________________    ATTRIBUTES OF THE STANDARD SWITCHBOARD PRODUCT                                (called QED-S)                                                                __________________________________________________________________________    QED-S                                                                         All standard parts                                                            <=4000A QED-2 Standard Designs                                                <=4000A MLO and Main Device line-ups                                          480 Vac maximum                                                               Aluminum or Copper Bus                                                        Up to 200kA SCCR                                                              Series ratings where available                                                Suitable for use as service equipment                                         NEMA Type 1 Enclosure                                                         NEMA Type 3R Enclosure non-walk-in                                            Fixed Individually Mounted Mains:                                             Thermal Magnetic M, P                                                         Micrologic M, P, SE                                                           Fusible BP                                                                    Fix Individuaily Mounted Feeders M, P and BP                                  Group Mounted Mains or Feeders:                                               Thermal Magnetic F, K, L, M, N                                                Micrologic L, M, N                                                            Fusible QMJ or QMB                                                            Options (where available):                                                    Auxiliary SW 1A and 1B                                                        Shunt Trip 120Vac                                                             Short time                                                                    Ground fault/GF pit                                                           Trip Indicators/Local current ammeter                                         Power Meter                                                                   Circuit Monitor                                                               Pull Box                                                                      Auxiliary Section                                                             Configurations (see QED-S Switchboard Line-Ups)                               QED-S Switchboard Line-ups Available In Q2C PS                                QED-S Single Mains                                                            QED-S Six Circuit Mains                                                       QED-S Combination Sections                                                    QED-S Types of Line-ups                                                       QED-S Single Mains                                                            Available as Single Main:    N/A as Single Mains:                             <4000A                       >4000A N/A                                       Service Entrance and Non-Service Entrance                                                                  QMJ single mains N/A                             M, P, SE, BP                 QMB <400A or >800A N/A                                                        QED-3 N/A                                                                     QED-4 N/A                                                                     DS, MP, and BS                                   Cable Feed: Top - Left, Right or Center                                                                    Busway, Transformer and Thru-bus feed to         Cable Feed: Bottom - Left, Right or Center                                                                 existing Switchboard N/A                         UCT available ahead of individually                                                                        Cold Sequence UCT N/A (pending)                  mounted mains (BP, P and SEF).                                                                             UCT/Main with Load Lugs N/A                                                   UCT ahead of group mounted I-LINE or             QMB                                                                                                        main devices. (pending)                          BP 4000A Top Feed only       4000A BP Bottom Feed N/A. Requires                                            auxiliary section ahead for bottom entry.                                     3000A Bottom Feed N/A with Circuit                                            Monitor.                                         Bussed Aux. ahead of individually mounted                                                                  Bussed Aux. N/A ahead of group mounted           and group mounted mains.     QMB or I-Line Single Mains.                      Combination sections are available in the                                                                  Combination sections (individually mounted       first section (single main & short distribution)                                                           device and short distribution in same            section)                                                                      or second section.           not available as distribution.                   Mains:                                                                        QED-2 IMD C/B 80A-4000A                                                       (M, P, SEF)                                                                   QED-2 IMD F/S 601-4000A                                                       (BP)                                                                          I-LINE C/B 300A-1200A                                                         (L, M, N - Back Fed)                                                          QMB F/S 300A-800A                                                             QED-S Six Circuit Mains                                                       Available as Six Circuit Mains (SCM):                                                                      N/A as Six Circuit Mains:                        <3000A Device Amps           >3000A Devices N/A                               Service Entrance Only        Thru-bus feed N/A                                System Amps <4000A Cable Feed                                                                              Busway and Transformer                                                        Combination sections are N/A in SCM              Mains available P, BP, I-LINE, QMB                                                                         DS, MP, BS, SEF, SED, M (IMD)                    1 Hot Sequence UCT available ahead of SCM                                                                  Cold Sequence UCT N/A                                                         A UCT ahead of each main N/A                     Bussed Aux. ahead of SCM     Empty Aux. ahead may result in two aux.                                       sections because a bussed Main Lug                                            Compartment is required to feed some             SCM's                                                                                                      Distribution (any type) not available fed                                     by SCM (cabled)                                                               City of Chicago local code N/A if SCM            Line-Up.                                                                      Mains:                                                                        QED-2 IMD C/B 300A-2500A (P) Six Circuit Mains feeding short interiors        QED-2 IMD F/S 601-3000A (BP,)                                                                              in same section N/A.                             I-LINE C/B 15-1200A.(F, K, L, M, N)                                           QMB F/S 10A-1200A            BP Six Circuit Mains N/A with <=2500A            QMJ F/S 100A-600A            Commonwealth UCT.                                QED-S Combination Sections                                                    Available in Combination Sections:                                                                         N/A in Combination Sections:                     (short I-LINE or QMB) <2000A >2000A N/A                                       Service Entrance & Non-Service Entrance                                                                    Busway, Transformer and Thru-Bus                                              connections N/A                                  Single main feeding group mounted                                                                          Individually mounted device as a                 distribution                                                                  distribution                 w/combination section N/A                        Circuit Breaker (M, P) in combination                                                                      SB, MP & DS N/A in combination sections          w/36" high I-LINE            BP>1600 Top Loc. N/A in combination              sections                                                                                                   BP>2000 Bot Loc. N/A in combination              sections                                                                                                   P>2000 80% Top Loc N/A in combination            sections                                                                                                   P>1600 100% Top Loc N/A in combo                 sections                                                                      BP switches in combination with 27" high                                                                   Circuit breaker (M, P) N/A in                    I-LINE or 30" high QMB       combination with 30" H QMB or                                                 19.5" meter-compartment (Circuit Monitor)        __________________________________________________________________________                                 N/A                                              QED-S Types of Line-ups                                                       Single Mains:                                                                 Single Main without Distribution.                                             Single Main with one type of Distribution (i.e. I-LINE, QMB/J, BP and IMD     C/B's).                                                                       Single Main with more that one type of Distribution.                          Single Main without Distribution                                              Individually Mounted (IMD) Single Mains are available without                 Distribution.                                                                 For Lug In Lug Out SM, Do NOT choose Thru-Bus = YES on the Switchboard        Requirements                                                                  Screen. The program will assume you want to feed Distribution!                Single Main with one Type of Distribution.                                    Individually Mounted (IMD) Single Mains are available with all types of       Distribution (I-LINE, QMB\QMJ, <2500 IMD circuit breakers,          <3000A IMD fusible switches).                                                 IMD Single Mains can be cable feed. IMD Single Main Circuit Breakers          (2000A maximum) can                                                           be combined in the same section with I-LINE Distribution short (36"high)      interiors. IMD Single                                                         Main Circuit Breakers can NOT be combined in the same section with            QMB\QMJ Distribution                                                short                                                                         (30"high) interiors. IMD Single Main BP Fusible Switches (2000A maximum)      can be combined                                                               in                                                                            the same section with I-LINE short (27"high) interiors or                     QMB\QMJ short (30"high) interiors.                                  Group Mounted Single mains are cable feed only.                               Group Mounted I-LINE Single Mains are available with I-LINE Distribution      ONLY.                                                                         Group Mounted I-LINE Single Mains can be mounted in any I-LINE interior       (>36"high).                                                                   Group Mounted QMB Single Mains are available with QMB or QMJ Distribution     ONLY.                                                                         Group Mounted QMB Single Mains have 46.5" of QMB\QMJ                Distribution mounting.                                                        Main Lugs Feeding Six Circuit Mains:                                          Six Circuit Mains are available in QED-S without Distribution.                Main Lug Feeding Distribution:                                                Main Lug feeding one type of Distribution (i.e. I-LINE, QMB/J, BP and IMD     C/B's).                                                                       Main Lug feeding more than one type of Distribution.                          Utility Metering (Hot Sequence Only!)                                         Commonwealth Edison UCT only. All other UCT's are currently N/A in            QED-S.                                                                        UCT Ahead of Single Main (with Distribution). Load lugs (no distribution)     N/A in QED-S.                                                                 UCT Ahead of Six Circuit Mains (Distribution off a Six Circuit Main           N/A).                                                                         Fusible Switchboard Dimensions                                                Bolt-Loc Type BP switches mount in 45" high mounting space for                Top or Bottom Located and 90" high for Middle Located.                        Thru-bus is required when any individually mounted device is connected        as                                                                            a Six Circuit Main or Branch Feeder.                                          The Depth and Width are determined by the BP ampacity and accessories:        BP                                                 Top Mid Bot                AMPS  Min  Min           Cap Phase    AM   BM      Mtg Mtg Mtg                Height                                                                              Width                                                                              Depth                                                                              4W  GFP  Trip                                                                              Failure                                                                            AM  VM   FD  PT's                                                                              45" 90" 45"                __________________________________________________________________________    BP 1600                                                                             24   30   N   N    N   N    N   N    N   N   Y   Y   Y                  BP 1600                                                                             24   36   Y   Y    N   N    Y   Y    Y   N   Y   N   N                  BP 1600                                                                             24   36   Y   Y    N   N    Y   Y    Y   Y   N   Y   Y                  BP 1600                                                                             24   36   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   N                  BP 1600                                                                             24   42   Y   Y    Y   Y    Y   Y    Y   N   Y   N   N                  BP 1600                                                                             24   42   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   Y                  BP 1600                                                                             24   48   Y   Y    Y   Y    Y   Y    Y   N   Y   N   N                  BP 1600                                                                             24   48   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   Y                  BP 2000                                                                             24   30   N   N    N   N    N   N    N   N   N   Y   Y                  BP 2000                                                                             24   36   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   N                  BP 2000                                                                             24   36   Y   Y    N   N    Y   Y    Y   Y   N   Y   Y                  BP 2000                                                                             24   42   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   Y                  BP 2000                                                                             24   48   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   Y                  BP 2500                                                                             24   36   N   N    N   Y    Y   Y    Y   Y   N   Y   N                  BP 2500                                                                             24   36   N   N    N   N    Y   Y    N   Y   N   N   Y                  BP 2500                                                                             24   42   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   Y                  BP 2500                                                                             24   48   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   Y                  BP 3000                                                                             36   36   N   N    N   Y    Y   Y    Y   Y   N   Y   N                  BP 3000                                                                             36   36   N   N    N   N    Y   Y    N   Y   N   N   Y                  BP 3000                                                                             36   42   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   Y                  BP 3000                                                                             36   48   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   Y                  BP 4000                                                                             48   42   N   N    N   Y    Y   Y    Y   Y   N   Y   N                  BP 4000                                                                             48   42   N   N    N   N    Y   Y    N   Y   N   N   Y                  BP 4000                                                                             48   48   Y   Y    Y   Y    Y   Y    Y   Y   N   Y   Y                  __________________________________________________________________________    2500A and 3000A NEMA Type 3R Switches must be in 42" or 48" wide              sections.                                                                     BP Switches can mount in the same section with:                               Utility CT Compartments (max. 45" high UCT mounting space),                   Other BP switches (max. 2000A bottom & max. 1200A top),                       30" high QMB/QMJ interiors,                                                   36" high I-LINE interiors.                                                    When a BP is through bus connected on the line and load sides                 (when a UCT or bused auxilairy section is ahead of a single main BP)          the section width is 36" wide min. with <=2000A BP, 42" wide min. for         2001-3000A BP                                                                 and 48" wide min. for a 4000A BP.                                             GLOSSARY                                                                      BP       Bolt-Lot Type BP Pressure contact single-throw 100% load rated                break switch per                                                              U.L. 977.                                                            C/B      Circuit Breaker                                                      Compression Lugs                                                                       Lugs that are crimped to hold cables.                                CMM      Commercial Multi-Metering                                            F/S      Fusible Switch                                                       I-LINE ®                                                                           Group mounted plug-on molded case circuit breaker 10-amps                     through 1200 amps,                                                            F frame through N frame; and group mounted Bolt-on molded case                circuit                                                                       breakers 10 amps through 400 amps, F frame through L freame.         IMD      "Individually Mounted Device" is mounted separately from other                devices and do                                                                not share through connections to three-bus with any other                     devices. One or two                                                           IMD can be mounted in one section.                                   Main Lugs                                                                              (MLO) are lugs used to terminate incoming cables. Main lugs are               used to connect                                                               six circuit                                                          QMB      Quick-Make, Quick-Break fusible switches are group mounted                    devices, 10 amps                                                              through 1200 amps.                                                   QMJ      Quick-Make, Quick Break fusible switches that are reduced in                  height to allow use                                                           with Class J fuses. QMJ switches are available 10 amps through                600 amps and                                                                  mounted in QMB interriors.                                           SCCR     Short Circuit Current Rating                                         Single Main                                                                            A device that will disconnect all load conductors from the                    service conductors.                                                  Six Circuit Mains                                                                      A group of devices that will disconnect all load conductors from              the                                                                           service conductors.                                                  Thermal Magnetic                                                                       A circuit breaker that combines thermal and magnetic trip                     actions to                                                                    provide over-current and short circuit protection.                   UCT      Utility Current Transformer Compartment                              UL       Underwriter's Laboratory                                             Stored Energy C/B                                                                      A circuit breaker which will open or close the device from a                  trip signal or                                                                push button                                                          Solid State C/B                                                                        A circuit breaker that uses current transformers solid-state                  circuitry and a                                                               flux transfer shunt trip to provide overload and short curcuit                protection.                                                          __________________________________________________________________________

                                      TABLE III                                   __________________________________________________________________________    SAMPLE ORDER PROCESSING FOR A STANDARD SWITCHBOARD                            __________________________________________________________________________    FEATURES :============================================================        01CA13XXXX00001demmdi03                                                                            Mine.BOM.Sub    999USAEELIBBY DALE'S TEST                                     Mine.Sub        Nashville TN1                                                 0005 4.0        11000110001                              02NASHVILLE                PRNTA                                                                             PRNTB d:\pfe\pfe.exe                                            /p                                       0301   1    01     1           0       0501                                   20004 11018 201                                                                              0                   0        Q1                                0350   1    50     1           0       0550NON                                49          2 2                                                               2           24D                                                               0331   1    31     1           0       0531 0SM                                                                           0206003P                          TM MA    N           Y                                                        DR20                                                                          4W             Y   02  00012                                                  0331   2    31     1           0       0531 0SM                               1001003PSOTM FA  N         Y                                                  DR20                                                                          4W             Y   10  00012                                                  0310   1    10     1           0       0510                                   CB120003P 2PX2000  SMLSIG8                                                    F0          O0         4W          W      Y N                                 04Mark It                                                                     05Detail It                                                                   QUOTE RESULTS: ======================================================         QUOTE TO CASH JOB NUMBER IS  CA13XXXX                                         01S                                                                           03954100954100  1    EA    B 0000033945.00 00000000.0000                      00000000.0000 0000.0000.0000 00000000.0000                                    0400000000.0000 00000000.0000 00000000.0000                                   0509411 9411 SQUARE D STANDARD QED SWITCHBOARD N N  N N N N                   06                                                                              POWER STYLE QED SWITCHBOARD                                                 06                                                                              DESIGNED AND TESTED IN ACCORDANCE WITH:                                     06                                                                              UL 891/NATIONAL ELECTRIC CODE/NEMA PB-2                                     06                                                                            06                                                                              2000A 480Y/277 VAC 3PH 4W  60HZ                                             06                                                                            06                                                                              SUITABLE FOR USE AS SERVICE ENTRANCE EQUIPMENT                              06                                                                              SHORT CRCT CURRENT RTNG:18 KA RMS SYM.                                      06                                                                              ACCESSIBILITY: FRONT AND LEFT SIDE                                          06                                                                              INCOMING: BOTTOM RIGHT/CABLE FED                                            06                                                                              BUSSING: PLATED AL BUS/UL891 HEAT RISE                                      06                                                                              SINGLE SECTION WITHOUT THRU-BUS                                             06                                                                            06                                                                              MAIN OVERCURRENT PROTECTION                                                 06                                                                              ---------------------------                                                 06                                                                              SM:                                                                         06 FIXED MOUNTED MICROLOGIC 80% C/B                                           06 2000A/3P PX2000 EQUIPPED WITH:                                             06 LONG, SHORT, INSTANTANEOUS, GFP                                            06 LOCAL CURRENT AMMETER                                                      06 TRIP INDICATOR                                                             06 CONTROL POWER FOR GF                                                       06 PUSH-TO-TEST                                                               06 SUPPLIED IN SWITCHBOARD                                                    06                                                                            06                                                                              SM DISTRIBUTION                                                             06                                                                              ----------------                                                            06                                                                              2 - 600/3P                                                                             I-LINE MOUNTED TYPE MA C/B'S                                       06         THERMAL MAGNETIC TYPE                                              06         EACH EQUIPPED WITH:                                                06                                                                              10 -                                                                              100/3PSO                                                                           I-LINE MOUNTED TYPE FA C/B'S                                       06         THERMAL MAGNETIC TYPE                                              06         EACH EQUIPPED WITH:                                                06                                                                            06                                                                              SPECIAL FEATURES                                                            06                                                                              ----------------                                                            06                                                                              STANDARD - ANSI 49                                                          06                                                                              ALUMINUM COMPRESSION LUGS ON:                                               06                                                                              SINGLE MAIN DEVICE                                                          06                                                                            06                                                                              TYPE 1 DIMENSIONS                                                           06                                                                              -------------------                                                         06                                                                              4' 0"W 24.0"D                                                               06                                                                              1 @ 48"W                                                                    $$TUUNIT SCHEDULE                                                             UNIT SCHEDULE FILE NOT PRESENT                                                $$TDDETAIL PRICING                                                            1    48"W SECTION NO THROUGH BUS                                                                        A           2500.00                                 1    I-LINE DOUBLE 48"W 2000A AL.36"H                                                                   B           0.00                                    1    PXF 2000 AMP 3 POLE GROUND TRIP                                                                    A           20630.00                                1    LOCAL CURRENT AMMETER,TRIP IND.                                                                    A           920.00                                  1    STD. AL. COMPRESSION LUGS                                                                          A           0.00                                    1    ULSE LABEL COMBO.IND.MTG.DEVICE                                                                    A           665.00                                  10   FA 3P SPACE ONLY 480V                                                                              A 50.00     500.00                                  2    MA 600A 3P 600V      A 4155.00   8310.00                                 1    PUSH TO TEST GFP QED2 IMD P                                                                        A           420.00                                                            B SECTION 1 TOTAL                                                                         33945.00                                     DELIVERY CODE        B ITEM TOTAL                                                                              33945.00                                     LINE CODE 9411                                                           ORDER RESULTS: == ===================================================                            PRICE/COST SUMMARY                                                            =====================                                      Q2C NUMBER:                                                                              CA13XXXX     DATE: JUN 25                                          1997                                                                          JOB NAME:    LIBBY DALE'S TEST                                                                        SALES OFFICE # 999                                    JOB LOCATION:                                                                              Nashville TN                                                                             DELIVERY                                              CODE: B                                                                       TOTALS FOR THIS QUOTE ITEM ARE:                                                           PRICE   COST       STANDARD COSTS                                             ------  -----      -----------------                              SPECIAL ITEMS                                                                             0.00    0.00       MATERIAL  1,932.72                             STD COMPONENTS                                                                            33,945.00                                                                             2,501.95   LABOR     382.30                                           -------------                                                                         -------------                                                                            BURDEN    126.31                                           33,945.00                                                                             2,501.95   VAR BURDEN                                                                              60.62                                SPECIAL ITEMS INCLUDED IN THIS QUOTE:                                         QTY                                                                              DESCRIPTION                                                                              DC PRICE EACH                                                                           COST EACH                                             ----                                                                             -------------                                                                            ---                                                                              ------------                                                                         -----------                                              NONE                                                                       ITEM DESCRIPTION FOR THIS QUOTE:                                              ITEM                                                                              DESCRIPTION           CATEGORY #                                          -----                                                                             ------------------------------------------                                                          -------------                                           SQUARE D STANDARD QED SWITCHBOARD                                                                   09411                                               Q2C NUMBER: CA13XXXX                                                                         ITEM:         PAGE : 1                                                       QUOTE BOM                                                                     ===========                                                     ITEM                                                                              DESIGNATION                                                                           DESCRIPTION                                                       -----                                                                             --------------                                                                        -------------                                                                 SQUARE D POWER STYLE SWITCHBOARD                                              ----------------------------------------                                      DESIGNED AND TESTED IN ACCORDANCE WITH:                                       UL 891/NATIONAL ELECTRIC CODE/NEMA PB-2                                       2000A 480Y/277 VAC 3PH 4W 60HZ                                                SUITABLE FOR USE AS SERVICE ENTRANCE EQUIPMENT                                SHORT CRCT CURRENT RTNG:18 KA RMS SYM.                                        ACCESSIBILITY: FRONT AND LEFT SIDE                                            INCOMING: BOTTOM RIGHT/CABLE FED                                              BUSSING: PLATED AL BUS/UL891 HEAT RISE                                        SINGLE SECTION WITHOUT THRU-BUS                                               MAIN OVERCURRENT PROTECTION                                                   ----------------------------------                                            SM:                                                                            FIXED MOUNTED MICROLOGIC 80% C/B                                              2000A/3P PX2000 EQUIPPED WITH:                                                LONG, SHORT, INSTANTANEOUS, GFP                                               LOCAL CURRENT AMMETER                                                         TRIP INDICATOR                                                                CONTROL POWER FOR GF                                                          PUSH-TO-TEST                                                                  SUPPLIED IN SWITCHBOARD                                                      SM DISTRIBUTION                                                               ------------------                                                             2 -                                                                             600/3P                                                                             I-LINE MOUNTED TYPE MA C/B'S                                                  THERMAL MAGNETIC TYPE                                                         EACH EQUIPPED WITH:                                                   10 -                                                                             100/3PSO                                                                           I-LINE MOUNTED TYPE FA C/B'S                                                  THERMAL MAGNETIC TYPE                                                         EACH EQUIPPED WITH:                                                   SPECIAL FEATURES                                                              -------------------                                                           STANDARD - ANSI 49                                                            ALUMINUM COMPRESSION LUGS ON:                                                 SINGLE MAIN DEVICE                                                            TYPE 1 DIMENSIONS                                                             --------------------                                                          4' 0"W 24.0"D                                                                 1 @ 48"W                                                          Q2C NUMBER: CA13XXXX                                                                         ITEM:         PAGE : 2                                                     ITEMIZED PRICE SHEET                                                          (For Internal Use Only)                                           QTY                                                                              DESCRIPTION          DELIVERY                                                                            LIST EACH  LIST TOTAL                           ----                                                                             ---------------------------------------                                                            ----------                                                                          ---------  -----------                          1  48"W SECTION NO THROUGH BUS                                                                        A                2500.00                              1  I-LINE DOUBLE 48"W 2000A AL.36"H                                                                   B                0.00                                 1  PXF 2000 AMP 3 POLE GROUND TRIP                                                                    A                20630.00                             1  LOCAL CURRENT AMMETER,TRIP IND.                                                                    A                920.00                               1  STD. AL. COMPRESSION LUGS                                                                          A                0.00                                 1  ULSE LABEL COMBO.IND.MTG.DEVICE                                                                    A                665.00                               10 FA 3P SPACE ONLY 480V                                                                              A     50.00      500.00                               2  MA 600A 3P 600V      A     4155.00    8310.00                              1  PUSH TO TEST GFP QED2 IMP P                                                                        A                420.00                                                       B     SECTION 1 TOTAL                                                                          33945.00                                DELIVERY CODE        B     ITEM TOTAL 33945.00                             LINE CODE 9411                                                                Q2C NUMBER: CA13XXXX                                                                         ITEM:         PAGE : 3                                         PSEUDO/BAY PART NO.      PLANT                                                                         43-45-46                                             BAY # 1                                                                       --------                                                                      A                                                                             SPCLA2                       P C/B/I-LINE LINE CONN. AL.1600A                                     .00  40.54    5.73  5.08  1.90 B ICBMTG                            1 80251-686-52  CM CM CM P C/B/I-LINE LINE CONN. AL.1600A            PXF362000G                   PXF 2000 AMP 3 POLE GROUND TRIP                                      20630.00                                                                           731.33   5.73  5.08  1.90 A ICBMTG                            1 PXF362000G    CM CM CM PXF 2000 AMP 3 POLE GROUND TRIP             SPIMTG48                     P CB MOUNTING ASSEMBLY 48"W                                          .00  6.78     5.73  5.08  1.90 A ICBMTG                            1 80251-610-53  CM CM CM P CB MOUNTING ASSEMBLY 48"W                 SPILLA2                      1600A 100% P LINE/LOAD LUG AL.                                       .00  68.09    12.90 2.03  0.76 A ICBTBC                            1 80251-604-52  CS CS CS                                                      1 80251-606-50  CS CS CS                                                      1 80251-633     CS CS CS                                             SSQ1B48                      NEMA 1 BACK COVER 48"W                                               .00  29.63    8.60  0.81  0.92 A CUSN1                             1 80231-519-65  CU CU CU NEMA 1 BACK COVER 48"W                      SSQ1S24                      NEMA 1 SIDE PLATE 24"DEEP                                            .00  11.88    8.60  0.81  0.92 A CUSN1                             2 80231-513-50  CU CU CU NEMA 1 SIDE PLATE 24"DEEP                   SSQ1S24                      NEMA 1 SIDE PLATE 24"DEEP                                            .00  11.88    8.60  0.81  0.92 A CUSN1                             2 80231-513-50  CU CU CU NEMA 1 SIDE PLATE 24"DEEP                   SGCD4836W                    I-LINE 48"DOUBLE 36"H COVER WIDE                                     .00  11.52    8.60  0.81  0.92 A CUDIL                             1 80235-552-63  CU CU CU                                                      1 TEXT          CU CU CU REF80235-616 FOR COVER LAYOUT               SPCCA48B                     P CB/I-LINE COVER 48"W BOT                                           .00  10.43    17.20 0.81  0.92 B CUIMD                             1 80251-694-55  CU CU CU P CB/I-LINE COVER 48"W BOT                  SPIFC48                      P FRONT COVER 48"W                                                   .00  16.70    17.20 0.81  0.92 A CUIMD                             1 80251-622-53  CU CU CU P FRONT COVER 48"W                          SULSEPA36                    PA-PE ULSE BARRIER >=36"W                                            .00  9.76     4.30  4.04  4.62 A CUULSE                            1 80251-642-50  FC FC CU PA-PE ULSE BARRIER >=36"W                   SSQ1LA                       TYPE 1 LIFTING ASSEMBLY                                              .00  2.97     0.00  0.00  0.00 A                                   1 80231-501-50  FR FR FR TYPE 1 LIFTING ASSEMBLY                     SSQ1F4824                    QED2 NEMA 1 48"W 24"D FRAME                                          .00  59.29    5.60  2.99  1.22 A SN1                               1 80231-500-55  FR FR FR                                                      1 80231-514-55  FR FR FR                                             SSQB4824                     QED2 BASE CHANNELS 48"W 24"D                                         .00  10.38    0.00  0.00  0.00 A                                   2 80231-517-06  FR FR FR                                                      2 80231-512-50  FR FR FR                                             SDIAL800                     CB NEUTRAL  LUG 401 TO 800 AMPS                                      .00  4.86     16.79 3.99  1.63 A DICL                              3 80031-002-09  ID ID IS CB NEUTRAL  LUG 401 TO 800 AMPS             SDIAL800                     CB NEUTRAL  LUG 401 TO 800 AMPS                                      .00  4.86     16.79 3.99  1.63 A DICL                              3 80031-002-09  ID ID IS CB NEUTRAL  LUG 401 TO 800 AMPS             SDIAL100                     CB NEUTRAL  LUG 30 TO 100 AMPS                                       .00  3.39     16.79 3.99  1.63 A DICL                              1 80235-612-50  ID ID IS CB NEUTRAL  LUG 30 TO 100 AMPS              SDIAL100                     CB NEUTRAL  LUG 30 TO 100 AMPS                                       .00  3.39     16.79 3.99  1.63 A DICL                              1 80235-612-50  ID ID IS CB NEUTRAL   LUG 30 TO 100 AMPS             FA34SO                       FA 3P SPACE ONLY 480V                                                50.00                                                                              0.53     4.20  3.99  1.63 A DICB                              1 40517-407-01  ID ID IS                                                      1 21427-20161   ID ID IS                                             MA36600                      MA 600A 3P 600V                                                      4155.00                                                                            185.72   4.20  3.99  1.63 A DICB                              1 MA36600       ID ID IS MA 600A 3P 600V                             FA34SO                       FA 3P SPACE ONLY 480V                                                50.00                                                                              0.53     4.20  3.99  1.63 A DICB                              1 40517-407-01  ID ID IS                                                      1 21427-20161   ID ID IS                                             FA34SO                       FA 3P SPACE ONLY 480V                                                50.00                                                                              0.53     4.20  3.99  1.63 A DICB                              1 40517-407-01  ID ID IS                                                      1 21427-20161   ID ID IS                                             FA34SO                       FA 3P SPACE ONLY 480V                                                50.00                                                                              0.53     4.20  3.99  1.63 A DICB                              1 40517-407-01  ID ID IS                                                      1 21427-20161   ID ID IS                                             FA34SO                       FA 3P SPACE ONLY 480V                                                50.00                                                                              0.53     4.20  3.99  1.63 A DICB                              1 40517-407-01  ID ID IS                                                      1 21427-20161   ID ID IS                                             FA34SO                       FA 3P SPACE ONLY 480V                                                50.00                                                                              0.53     4.20  3.99  1.63 A DICB                              1 40517-407-01  ID ID IS                                                      1 21427-20161   ID ID IS                                             FA34SO                       FA 3P SPACE ONLY 480V                                                50.00                                                                              0.53     4.20  3.99  1.63 A DICB                              1 40517-407-01  ID ID IS                                                      1 21427-20161   ID ID IS                                             FA34SO                       FA 3P SPACE ONLY 480V                                                50.00                                                                              0.53     4.20  3.99  1.63 A DICB                              1 40517-407-01  ID ID IS                                                      1 21427-20161   ID ID IS                                             FA34SO                       FA 3P SPACE ONLY 480V                                                50.00                                                                              0.53     4.20  3.99  1.63 A DICB                              1 40517-407-01  ID ID IS                                                      1 21427-20161   ID ID IS                                             FA34SO                       FA 3P SPACE ONLY 480V                                                50.00                                                                              0.53     4.20  3.99  1.63 A DICB                              1 40517-407-01  ID ID IS                                                      1 21427-20161   ID ID IS                                             MA36600                      MA 600A 3P 600V                                                      4155.00                                                                            185.72   4.20  3.99  1.63 A DICB                              1 MA36600       ID ID IS MA 600A 3P 600V                             SGNGGD4836                   I-LINE 48"DR 36" GUTTER GUARD                                        .00  2.68     0.00  0.00  0.00 A                                   2 80235-812-51  IM IM IM I-LINE 48"DR 36" GUTTER GUARD               SGID48A2036                  I-LINE DOUBLE 48"W 2000A AL.36"H                                     0.00 194.03   15.39 2.99  1.22 B DI36                              1 80235-611-65  IS IS IS                                                      1 80235-553-52  IM IM IM                                                      2 80231-515-52  IM IM IM                                             SSISULLABEL                  UL LABEL SINGLE SECTION                                              .00  0.00     0.00  0.00  0.00 A CULABEL                           1 80258-117-77  LA LA LA UL LABEL SINGLE SECTION                     SILSULLABEL                  UL LABEL I-LINE SECTIONS                                             .00  1.42     0.00  0.00  0.00 A CULABEL                           1 80258-117-55  LA LA LA UL LABEL I-LINE SECTIONS                    SULSE                        ULSE BARRIER REQUIRED                                                .00  0.00     4.30  4.04  4.62 A CUULSE                            1 TEXT          LA LA LA ULSE BARRIER REQUIRED                       SIMDCPCGULSE                 ULSE LABEL COMBO.IND.MTG.DEVICE                                      665.00                                                                             6.18     0.00  0.00  0.00 A CULABEL                           1 80258-135-51  LA LA LA                                                      1 80258-117-62  LA LA LA                                             PE20CT2                      PE/X NEUTRAL CT 2000 AMP                                             .00  40.96    46.80 3.94  1.64 A WCBGFI                            1 PE20CT2       MW MW MW PE/X NEUTRAL CT 2000 AMP                    SCBLCATIPX                   LOCAL CURRENT AMMETER,TRIP IND.                                      920.00                                                                             34.60    18.72 3.94  1.64 A WCBACC                            1 ALAMP         MW MW MW LOCAL CURRENT AMMETER,TRIP IND.             PTTQ2P4                      PUSH TO TEST GFP QED2 IMD P                                          420.00                                                                             19.69    5.73  5.08  1.90 A ISEMTG                            1 80251-786-58  MW MW MW PUSH TO TEST GFP QED2 IMD P                 SGFPTT4                      GFP PUSH TO TEST INSTALLED                                           .00  .00      18.72 3.94  1.64 A WCBACC                            1 TEXT          MW MW MW GFP PUSH TO TEST INSTALLED                  SPCNA48YCD                   P C/B /I-LINE NEUTRAL/GFI 48"W                                       .00  207.94   17.77 1.44  0.78 B ICBNBC                            1 80251-695-61  NC NC NC                                                      1 80247-855-51  NC NC NC                                                      1 80235-620-53  NC NC NC                                             SPCNA48YCD                   P C/B /I-LINE NEUTRAL/GFI 48"W                                       .00  207.94   17.77 1.44  0.78 B ICBNBC                            1 80251-695-61  NC NC NC                                                      1 80247-855-51  NC NC NC                                                      1 80235-620-53  NC NC NC                                             SGBEI2000A24                 GROUND BUS EXTENSION AL 24D                                          .00  7.24     0.00  0.00  0.00 A                                   1 80235-791-60  TM TM TM GROUND BUS EXTENSION AL 24D                 SGB20A48                     GROUND BUS 2000A ALUMINUM 48"W                                       .00  3.56     5.60  2.00  0.82 A BHCB20                            1 80247-574-56  TS TS TS                                                      1 80247-574-50  TS TS TS                                             SGBLUG                       GROUND LUG ASSEMBLY ULSE SINGLE SEC                                  .00  0.00     0.00  0.00  0.00 A                                   1 80247-754-50  TS TS TS GROUND LUG ASSEMBLY ULSE SINGLE SEC         SSASC48                      48"W SECTION NO THROUGH BUS                                          2500.00                                                                            0.00     0.00  0.00  0.00 A                          SGMD48                       I-LINE DOUBLE 48"W MTG ASSEMBLY                                      .00  0.00     4.20  2.00  0.82 A DIMTG                    SCBSCL                       STD. AL. COMPRESSION LUGS                                            0.00 0.00     18.72 3.94  1.64 A WCBACC                            1 TEXT          ZZ ZZ ZZ STD. AL. COMPRESSION LUGS                   BAY PRICE                                                                              BAY MAT. COST                                                                             BAY LAB. COST                                                                            BAY BURD. COST                                33945.   2187.       484.       70.                                           TOTAL PRICE                                                                            TOTAL MATERIAL                                                                            TOTAL LABOR                                                                              TOTAL BURDEN                                  33945.   2187.       484.       70.                                           LINE CODE                                                                     PELT CODE B                                                                   __________________________________________________________________________

                                      TABLE IV                                    __________________________________________________________________________    DRAWING NOTES                                                                 GENERAL NOTES                                                                 __________________________________________________________________________    INCOMING FEED:     CABLED, BOTTOM RIGHT                                       SYSTEM VOLTAGE:    480Y/277 3-PH 4-W                                          AVAILABLE FAULT CURRENT:                                                                         18,000 A RMS SYM                                           SYSTEM AMPERAGE:   2000 AMPS                                                  BUS MATERIAL:      ALUMINUM &/OR COPPER                                       ACCESSIBILITY:     FRONT AND LEFT SIDE                                        HANDLING:          ROLLERS AND LIFTING                                        ENCLOSURE:         TYPE 1 FREE STANDING                                       COLOR:             ANSI 49                                                    UL LABEL:          DEADFRONT AND SUITABLE FOR USE                                                AS SERVICE ENTRANCE WHEN NOT                                                  MORE THAN SIX MAIN DISCONNECTING                                              MEANS ARE PROVIDED                                         ALUMINUM COMPRESSION LUGS ON:                                                                    SINGLE MAIN DEVICE                                         SWBD MK:           MARK IT                                                    SINGLE SECTION WITHOUT THRU-BUS                                               __________________________________________________________________________

                                      TABLE V                                     __________________________________________________________________________    TABLE OF MODULES AND COMPONENTS INCLUDED IN THE SWITCHBOARD ORDER             POWER STYLE QED SWITCHBOARD                                                   SECT.                                                                             CKT.               TYPE/                                                                              FUSE/                                                                             LUG                                                                              LUG ACCESSORY/SIRING                       NO. NO.                                                                              DESIGNATION                                                                           N/P                                                                              AMPS/P                                                                             FRAME                                                                              TRIP                                                                              QTY.                                                                             SIZE                                                                              DIAGRAM NUMBER                         __________________________________________________________________________    1   SM         No 2000/3                                                                             PX2000                                                                             LSIG                                                                              6  3/0-750                                                                           W GT/80310-401, F 0                    1   1          No 100/3                                                                              FA50     1  #12-1/0                                    1   2          No 100/3                                                                              FA50     1  #12-1/0                                    1   3          No 100/3                                                                              FA50     1  #12-1/0                                    1   4          No 600/3                                                                              MA       3  3/0-500                                    1   5          No 100/3                                                                              FA50     1  #12-1/0                                    1   6          No 100/3                                                                              FA50     1  #12-1/0                                    1   7          No 100/3                                                                              FA50     1  #12-1/0                                    1   8          No 100/3                                                                              FA50     1  #12-1/0                                    1   9          No 600/3                                                                              MA       3  3/0-500                                    1   10         No 100/3                                                                              FA50     1  #12-1/0                                    1   11         No 100/3                                                                              FA50     1  #12-1/0                                    1   12         No 100/3                                                                              FA50     1  #12-1/0                                    __________________________________________________________________________

What is claimed is:
 1. A method of re-engineering a product linecomprising the steps of:a) interviewing individual customers to identifyand understand actual needs of the individual customers beyond what thecustomers indicate in product specifications; b) from the actual needsof the individual customers beyond what the customers indicate inproduct specifications, revising product specifications to more closelycorrespond to actual needs of groupings of customers; c) identifying asubset of product configurations that in various combinations satisfy amajority of the actual needs of the groupings of customers; d)standardizing and streamlining a process of ordering and manufacturingstandard designs from the subset of product configurations; and e)manufacturing a product that is ordered using the resulting standardizedand streamlined process of ordering, said product being manufacturedusing said standardized and streamlined process of manufacturingstandard designs.
 2. The method as claimed in claim 1, which includesidentifying the actual needs of groupings of customers by extrapolatingfrom the actual needs of the individual customers beyond what thecustomers indicate in product specifications.
 3. The method as claimedin claim 1, which includes preparing a histogram of frequency ofcustomer orders for existing designs in order to identify the subset ofproduct configurations that in various combinations satisfy a majorityof the actual needs of the groupings of customers.
 4. The method asclaimed in claim 1, which includes ranking existing designs with respectto complexity of the existing designs, in order to identify existingdesigns that are frequent but are not complex and to include in saidsubset of product configurations the existing designs that are frequentbut are not complex.
 5. The method as claimed in claim 1, wherein themajority of the actual needs of the groupings of customers is monitoredas a percentage of customer orders satisfied by product designs fallingwithin the subset of product configurations, and the percentage isselected to balance cost of engineering and manufacturing of customdesigns for customer orders of products excluded from the subset ofproduct configurations versus cost of manufacturing standard designs forcustomer orders of products included in the subset of productconfigurations.
 6. The method as claimed in claim 5, wherein thepercentage is selected to be about 80%.
 7. The method as claimed inclaim 1, which includes performing custom design to satisfy customerorders of products in said product line that are excluded from thesubset of product configurations, and performing automatic configurationto satisfy customer orders of products in said product line that areincluded in the subset of product configurations.
 8. The method asclaimed in claim 1, which further includes revising a process of customdesign and manufacture of non-standard configurations to maximize use ofstandard components used in the manufacturing of standard designs. 9.The method as claimed in claim 8, which includes optimizing plant layoutto include an assembly line having stations for the manufacturing of thestandard designs, and a separate plant area for custom assembly.
 10. Themethod as claimed in claim 9, which includes diverting partiallyassembled product from the assembly line to the separate plant area forcustom assembly.
 11. The method as claimed in claim 10, which furtherincludes returning an assembled product from the separate plant area forcustom assembly to the assembly line to perform testing of standardproducts and custom products.
 12. The method as claimed in claim 1,wherein the process of ordering and manufacturing standard designs fromthe subset of product configurations is streamlined to manufacture aproduct from a standard design in about one day prior to a delivery daterequested by the customer.
 13. The method as claimed in claim 1, whereinthe process of ordering and manufacturing standard designs from thesubset of product configurations is streamlined by automatic processingof orders in an integrated computer system including an order-to-paymentsystem, a product selector for selecting standard products and customproducts, a configuration program for automatic configuration ofstandard products, and a materials management system.
 14. The method asclaimed in claim 13, wherein the integrated computer systemautomatically schedules manufacturing of standard products and orderingof parts for the standard products.
 15. A method of re-engineering aproduct line comprising the steps of:a) identifying a subset of productconfigurations that in various combinations satisfy a majority of theactual needs of customers; b) standardizing and streamlining a processof ordering and manufacturing standard designs from the subset ofproduct configurations; c) revising a process of custom design andmanufacture of non-standard configurations to maximize use of standardcomponents used in the manufacturing of standard designs; and d)manufacturing a product that is ordered using the resulting standardizedand streamlined process of ordering, said product being manufacturedusing either said standardized and streamlined process of manufacturingstandard designs or said revised process of custom design andmanufacture of non-standard configurations.
 16. The method as claimed inclaim 15, which includes preparing a histogram of frequency of customerorders for existing designs in order to identify the subset of productconfigurations that in various combinations satisfy a majority of theactual needs of the customers.
 17. The method as claimed in claim 15,which includes ranking existing designs with respect to complexity ofthe existing designs, in order to identify existing designs that arefrequent but are not complex and to include in said subset of productconfigurations the existing designs that are frequent but are notcomplex.
 18. The method as claimed in claim 15, wherein the majority ofthe actual needs of the customers is monitored as a percentage ofcustomer orders satisfied by product designs falling within the subsetof product configurations, and the percentage is selected to balancecost of engineering and manufacturing of custom designs for customerorders of products excluded from the subset of product configurationsversus cost of manufacturing standard designs for customer orders ofproducts included in the subset of product configurations.
 19. Themethod as claimed in claim 18, wherein the percentage is selected to beabout 80%.
 20. The method as claimed in claim 15, which includesperforming custom design to satisfy customer orders of products in saidproduct line that are excluded from the subset of productconfigurations, and performing automatic configuration to satisfycustomer orders of products in said product line that are included inthe subset of product configurations.
 21. The method as claimed in claim20, which includes optimizing plant layout to include an assembly linehaving stations for the manufacturing of the standard designs, and aseparate plant area for custom assembly.
 22. The method as claimed inclaim 21, which includes diverting partially assembled product from theassembly line to the separate plant area for custom assembly.
 23. Themethod as claimed in claim 22, which further includes returning anassembled product from the separate plant area for custom assembly tothe assembly line to perform testing of standard products and customproducts.
 24. The method as claimed in claim 15, wherein the process ofordering and manufacturing standard designs from the subset of productconfigurations is streamlined to manufacture a product from a standarddesign in about one day prior to a delivery date requested by thecustomer.
 25. The method as claimed in claim 15, wherein the process ofordering and manufacturing standard designs from the subset of productconfigurations is streamlined by automatic processing of orders in anintegrated computer system including an order-to-payment system, aproduct selector for selecting standard products and custom products, aconfiguration program for automatic configuration of standard products,and a materials management system.
 26. The method as claimed in claim25, wherein the integrated computer system automatically schedulesmanufacturing of standard products and ordering of parts for thestandard products.
 27. The method as claimed in claim 15, which includesinterviewing individual customers to identify and understand actualneeds of the individual customers beyond what the customers indicate inproduct specifications; and from the actual needs of the individualcustomers beyond what the customers indicate in product specifications,revising product specifications to more closely correspond to actualneeds of groupings of the customers.
 28. The method as claimed in claim27, wherein said subset of product configurations includes respectiveproduct configurations to satisfy the actual needs of the groupings ofcustomers.
 29. A method of re-engineering a product line comprising thesteps of:a) identifying a subset of product configurations that invarious combinations satisfy a majority of the actual needs ofcustomers; b) standardizing and streamlining a process of ordering andmanufacturing standard designs from the subset of productconfigurations; c) revising a process of custom design and manufactureof non-standard configurations to maximize use of standard componentsused in the manufacturing of standard designs; d) integrating a productconfiguration system for automatic configuration of the standard designsinto a computer system having an order-to-payment system, a productselector for selecting standard products and custom products, aconfiguration program for automatic configuration of standard products,and a materials management system; e) performing custom design tosatisfy customer orders of products in said product line that areexcluded from the subset of product configurations, and performingautomatic configuration to satisfy customer orders of products in saidproduct line that are included in the subset of product configurations;and f) manufacturing a product using either said custom design or saidautomatic configuration.
 30. The method as claimed in claim 29, whichincludes optimizing plant layout to include an assembly line havingstations for the manufacturing of the standard designs, and a separateplant area for custom assembly.
 31. The method as claimed in claim 30,which includes diverting partially assembled product from the assemblyline to the separate plant area for custom assembly.
 32. The method asclaimed in claim 31, which further includes returning an assembledproduct from the separate plant area for custom assembly to the assemblyline to perform testing of standard products and custom products. 33.The method as claimed in claim 29, wherein the process of ordering andmanufacturing standard designs from the subset of product configurationsis streamlined to manufacture a product from a standard design in aboutone day prior to a delivery date requested by the customer.
 34. A methodof re-engineering a product line comprising the steps of:a) interviewingindividual customers to identify and understand actual needs of theindividual customers beyond what the customers indicate in productspecifications; b) from the actual needs of the individual customersbeyond what the customers indicate in product specifications, revisingproduct specifications to more closely correspond to actual needs ofgroupings of customers; c) identifying a subset of productconfigurations that in various combinations satisfy a majority of theactual needs of the groupings of customers; d) standardizing andstreamlining a process of ordering and manufacturing standard designsfrom the subset of product configurations; e) revising a process ofcustom design and manufacture of non-standard configurations to maximizeuse of standard components used in the manufacturing of standarddesigns; f) integrating a product configuration system for automaticconfiguration of the standard designs into a computer system having aproduct selector for standard and custom products; g) performing customdesign to satisfy customer orders of products in said product line thatare excluded from the subset of product configurations, and performingautomatic configuration to satisfy customer orders of products in saidproduct line that are included in the subset of product configurations;and h) manufacturing a product using either said custom design or saidautomatic configuration.
 35. The method as claimed in claim 34, whichincludes optimizing plant layout to include an assembly line havingstations for the manufacturing of the standard designs, and a separateplant area for custom assembly.
 36. The method as claimed in claim 35,which includes diverting partially assembled product from the assemblyline to the separate plant area for custom assembly.
 37. The method asclaimed in claim 36, which further includes returning an assembledproduct from the separate plant area for custom assembly to the assemblyline to perform testing of standard products and custom products. 38.The method as claimed in claim 34, wherein the process of ordering andmanufacturing standard designs from the subset of product configurationsis streamlined to manufacture a product from a standard design in aboutone day prior to a delivery date requested by the customer.
 39. Themethod as claimed in claim 34, wherein the product selector isintegrated with an order-to-payment system, and the method includesintegrating the product configuration system with a materials managementsystem.
 40. A method of manufacturing items that are assembled inrespective configurations to satisfy individual customer orders, saidmethod comprising the steps of:a) receiving respective customerspecifications for the items; b) determining whether or not the customerspecification for each item can be met by a respective standard designconfiguration from a predefined set of standard designs and a predefinedset of standard components; and when the customer specification for saideach item can be met by a respective standard design configuration fromthe predefined set of standard designs and the predefined set ofstandard components, automatically producing manufacturing instructionsfor the respective standard design configuration from the customerspecification for said each item; and when the customer specificationfor said each item cannot be met by a respective standard designconfiguration from the predefined set of standard designs and thepredefined set of standard components, producing manufacturinginstructions for a custom design configuration that will meet thecustomer specifications for said each item; and c) manufacturing saideach item using either the manufacturing instructions for the respectivestandard design configuration or the manufacturing instructions for thecustom design configuration.
 41. The method as claimed in claim 40,wherein each respective standard design configuration is a combinationof selected ones of the standard designs, wherein the selected ones ofthe standard designs are standard designs for sub-assemblies included insaid each respective standard design configuration.
 42. The method asclaimed in claim 40, wherein the items are items of electricalequipment.
 43. The method as claimed in claim 40, wherein themanufacturing instructions automatically produced for the respectivestandard design configuration include a set of assembly drawings and abill of materials for said each item.
 44. The method as claimed in claim40, which includes operating a digital computer system programmed forautomatically determining whether or not the customer specification foreach item can be met by a respective standard design configuration froma predefined set of standard designs and a predefined set of standardcomponents; and when the customer specification for said each item canbe met by a respective standard design configuration from the predefinedset of standard designs and the predefined set of standard components,for automatically producing the manufacturing instructions for therespective standard design configuration from the customer specificationfor said each item.
 45. The method as claimed in claim 44, wherein thedigital computer system is programmed with a product selector programand a materials management system program, and the method furtherincludes operating the digital computer system for entering the customerorders, automatically producing the manufacturing instructions for thestandard design configurations, automatically ordering parts for theitems manufactured according to the manufacturing instructions for thestandard design configurations, and automatically scheduling assembly ofthe items manufactured according to the manufacturing instructions forthe standard design configurations.
 46. The method as claimed in claim40, wherein the manufacture of items according to the standardizeddesign configurations is optimized and separated from the manufacture ofitems according to the custom design configurations.
 47. The method asclaimed in claim 40, wherein a requested delivery date is received withthe customer specification for said each item, and when the customerspecification for said each item can be met by a respective standarddesign configuration from the predefined set of standard designs and thepredefined set of standard components, the manufacturing instructionsare used to manufacture said each item about one day prior to therequested delivery date.
 48. The method as claimed in claim 47, whichincludes charging a customer a premium price when a duration in time,from receipt of the customer specification to the requested deliverydate, is substantially shorter than a duration in time that is generallyrequired for designing and manufacturing an item according to a customdesign configuration.
 49. The method as claimed in claim 40, wherein theset of standard designs is predefined so that specifications from about80% of customer orders for the items are satisfied by standard designconfigurations and specifications from the remaining percentage ofcustomer orders for the items are satisfied by custom designconfigurations.
 50. The method as claimed in claim 40, wherein the setof standard designs is predetermined by an analysis of actual needs ofcustomers for said items, and by identifying a subset of existingdesigns of said items that can satisfy the actual needs of at least amajority of the customers.
 51. The method as claimed in claim 50,wherein the analysis of actual needs of customers includes customerinterviews.
 52. The method as claimed in claim 51, wherein the customerinterviews are used to determine when customers are specifyingcomplexity that they do not actually need.
 53. The method as claimed inclaim 50, wherein the step of identifying a subset of existing designsof said items that can satisfy the actual needs of at least a majorityof the customers includes preparing a histogram of frequency of customerorders for the existing designs.
 54. The method as claimed in claim 50,which further includes ranking the existing designs with respect tocomplexity of the existing designs, in order to identify existingdesigns that are frequent but are not complex and to include in saidsubset of existing designs the existing designs that are frequent butare not complex.
 55. The method as claimed in claim 40, wherein the setof standard designs is predetermined by including, in the set ofstandard designs, new designs that have been submitted to customers forcustomer approval prior to receipt of customer orders for the newdesigns.
 56. The method as claimed in claim 40, wherein humanparticipation and judgement are used in the production of manufacturinginstructions for the custom design configurations that will meet thecustomer specifications.
 57. The method as claimed in claim 40, whichfurther includes indicating why a customer specification for an itemcannot be met by a respective standard design configuration from thepredefined set of standard designs and the predefined set of standardcomponents.
 58. A method of re-engineering of a product line of itemsthat are assembled in respective configurations to satisfy individualorders, said method comprising the steps of:a) conducting a review ofmanufacturing and sales of the items, including customer interviews todetermine discrepancies between actual needs of the customers andcustomer needs expressed in respective customer specifications for theitems; b) selecting a reduced set of standard product configurationclasses so that a predefined majority of customer orders can besatisfied by the standard product configuration classes; c) optimizingmanufacturing capabilities for manufacturing of the items from thestandard product configuration classes; and d) processing customerorders by determining whether or not a respective product specificationassociated with each customer order can be satisfied by an itemconfigured from the standard product configuration classes; when therespective product specification can be satisfied by an item configuredfrom the standard product configuration classes, producing manufacturinginstructions for the item by configuring the item from the standardproduct configuration classes; and when the respective productspecification cannot be satisfied by an item configured from thestandard product configuration classes, producing manufacturinginstructions for the item by a custom design process; and e)manufacturing a product using either said manufacturing instructionsproduced by configuring the product from the standard productconfiguration classes, or said manufacturing instructions produced bysaid custom design process.
 59. The method as claimed in claim 58,wherein the items are items of electrical equipment.
 60. The method asclaimed in claim 58, which includes operating a digital computer systemprogrammed for automatically determining whether or not the respectiveproduct specification can be satisfied by an item configured from thestandard product configuration classes; and when the respective productspecification can be satisfied by an item configured from the standardproduct configuration classes, for automatically producing manufacturinginstructions for the item by configuring the item from the standardproduct configuration classes.
 61. The method as claimed in claim 60,wherein the manufacturing instructions automatically produced for theitem include a set of assembly drawings and a bill of materials for theitem.
 62. The method as claimed in claim 60, wherein the digitalcomputer system is programmed with a product selector program and amaterials management system program, and the method further includesoperating the digital computer for entering the customer orders; andwhen the respective product specification can be satisfied by an itemconfigured from the standard product configuration classes, forautomatically producing manufacturing instructions for the item byconfiguring the item from the standard product configuration classes andfor automatically scheduling assembly of the item.
 63. The method asclaimed in claim 58, wherein a requested delivery date is associatedwith each customer order, and when the respective product specificationcan be satisfied by an item configured from the standard productconfiguration classes, the manufacturing instructions are used tomanufacture the item about one day prior to the requested delivery date.64. The method as claimed in claim 58, wherein the reduced set ofstandard product configuration classes is selected so that productspecifications associated with about 80% of customer orders for theitems are satisfied by standard design configurations and specificationsassociated with the remaining percentage of customer orders for theitems are satisfied by custom design configurations.
 65. The method asclaimed in claim 58, wherein the selecting of the reduced set ofstandard product configuration classes includes preparing a histogram offrequency of customer orders for existing designs for the items.
 66. Themethod as claimed in claim 65, which further includes ranking theexisting designs with respect to complexity of the existing designs, inorder to identify existing designs that are frequent but are not complexand to include in said reduced set of standard product configurationclasses the existing designs that are frequent but are not complex. 67.The method as claimed in claim 58, wherein the selecting of the reducedset of standard product configuration classes includes submitting newdesigns to customers for customer approval prior to receipt of customerorders for the new designs, and including approved new designs in thereduced set of standard product configuration classes.
 68. The method asclaimed in claim 58, which includes implementation of a sales office andmanufacturing plant roll-out schedule for switching over from customdesign and assembly of the items in the product line to the processingof customer orders in accordance with said step d).
 69. The method asclaimed in claim 68, which includes using computer-based spreadsheettools for monitoring the implementation of the sales office andmanufacturing plant roll-out schedule.